Case Tractor 580c 580ck Loader Backhoe Workshop Manual by www.heydownloads.com

580C LOADER BACKHOE TABLE OF CONTENTS AND SERVICE MANUAL INTRODUCTION Table of Contents SERIES/SE CTION 10

SECTION NO.

SERIES - GENERAL General Engine Specification 207 Diesel Engine . . . . . . • . . . . . . . . . . . • . • Detailed Engine Specifications 207 Diesel Engine . . . . . . . . . . . . . • . . . . . . . Maintenance and Lubrication . . . . . . . . . . . . . . . . . Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . Noise Control . . . . . . . . . . . . . . . . . . . • . . . . . . .

FORM NO.

1010

9-79315

1026 1050 1051 1052

9-78685 9-66015 9-66015 9-66015

2001 2002 2015

9-78875 9-78825 9-78836

2035 2045

9-78866 9-78885

2050 2051 2053 2055 2125 2555

9-66015 9-66015 9-66015 9-78816 9-78845 9-78985

3010 3012 3013 3052

9-78785 9-78795 9-78806 9-66015

4002 4005 4007 4034

9-66015 9-66015 9-66015 9-66015

4090 4107 4109 4121

9-66015 9-66015 9-66015 9-66015

SERIES - STEERING SYSTEM Hydraulic Diagram, Trouble Shooting and Pressure Check . . . . . . . . . . . . . . . . . • . . . . 5002 Steering Pump . . . . . . . . . . . . . . . . . . . • . • . • . • 5005

9-66015 9-66015

SERIES - ENGINE Engine Diagnosis . . . . . . • . . . . . . . . . . . • . • • • . . Engine Tune-Up . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head, Valve Train and. Camshaft . • . • . . • . Crankshaft, Bearings, Flywheel and Oil Seals . . . . . . . . • . . . . . . . • . . . . • . . • . . Oil PuInp .......•••.•.•...•...••...... Stall Checks, Engine Removal and Installation, and Radiator . . . . . . • . . . . . . . . . • • . . . . . . Air Cleaner and Spark Arresting Muffler ...••••. Ether Injection . . . . . . . • . . . . . . • . . . . . • . . . .. Cooling System .............••.....•••.. Cylinder. Block, Sleeves, Pistons and Rods . . . . . . . Engine Lubrication . . • . . . . . • . • • . . . . . . . . • . . SERIES - FUEL SYSTEM Fuel Filters . . . . . . . . . . . . . . . • . . . • . . . . . • • • Fuel Injection PuInp . . . . . . . . . . . . . . . . . . . . . • . Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Controls, Fuel Lines and Fuel Tank . . . . . . . SERIES - HYDRAULIC SYSTEM Hydraulic Diagrams , Maintenance, Trouble Shooting and Pressure Checks . . . . . . . . . . . . . Hydraulic PUInp . . . . . . • . . . . . . . . . . . . . . . . . . Loader Control Valve . . . . . . . . . . . . . . . . . . . . . Three Point Hitch Control Valve . . . . . . . . . . . . . . Loader, Backhoe and Three Point Hitch Cylinders . . . . . . . . . . . . • • . . . . . . • • . . • • Backhoe Control Valve ............•.•.•.•. Stabilizer Control Valve . . . . • . . • . . . . . . • • • . . . Boom Lock System . . . . . • . . • . • . • . . . • . . . . . .

J I Case A Tenneco Company

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C. E. Div. 9-66017 580C Loader Backhoe April 1978

PRINTED IN U.S.A .

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SERIES/SECTION 50

SECTION NO.

FORM NO.

SERIES - Steering System (ContI d) Steering Control Valve . . . . . • • . . • • • . • . • • • • • . 5007 Steering Cylinders . . . . . . . . • • • • • . . • . . • . • • • • 5010 Front Axle . . • . • . . . . . • • • • • . . • • • • • . . . . . . . 5021

9-66015 9-66015 9-66016

SERIES - POWER TRAIN Power Shuttle Operation, Oil Flow Diagrams, Trouble Shooting and Maintenance . . . • • . . . . . Power Shuttle and Torque Converter . • . . . • . • • . . • Shuttle Controls (Power and Mechanical) • • • • . . . . . Transaxle Removal and Installation . . . . . . . . . . • . • Transaxle and Differential Lock . . . • . . . . . . . . • • . Drive Shaft . . • . . . . . . . . . . . . . • . . . . . . . . . • . 'Wheels and Tires . . • • . . . . . . . . . . . . • • . . . . . . . Clutch and Pressure Plate . . . . . . . . . . . . • • • . . . . Two Speed Mechanical Shuttle . . . . • . . . • . • . • . . .

6202 6210 6211 6212 6214 6222 6229 6406 6410

9-66015 9-66016 9-66015 9-66015 9-79236 9-66015 9-66015 9-66015 9-79116

SERIES - BRAKES Brakes (Pedals to Transaxle) . . . . . . . . . • . • . . • . 7106 Self Adjusting Differential Brakes . . . • . . . • . . . . • 7122

9-66016 9-79245

SERIES - ELECTRICAL SYSTEM Trouble Shooting . . . . . . . . . . • . . . . . . . . . . . . • . 8002 Wiring Diagrams • . . . . • ~ . . . . . . . • . • . . . . . • . • 8003 Instrument Panel and Instrument Cluster • • • . . • . . . 8004 Battery . . . . . . . . • . . . . • • • . . • . • . • . . . • • • . . 8005 Starter and Starter Solenoid . • . . . . . . . • • • . . . . • 8006 Nippondenso Starter . . . . . . . . . . . . . . . . . . . . . . 8006A Alternator • . • • . . . . . . . • . . . . . . . . . . . . . . . . 8007 Electrical Accessories . . . . . . . • . • . . • . . . . . . . 8015

9-66015 9-66015 9-66015 9-66015 9-66015 9-66015 9-66015 9-66016

SERIES - MOUNTED EQUIPMENT Loader •.•..•..............•.•.•••..• Three Point Hitch ..•.•••••••••..•••..•.•. ROPS Cab and Canopy . . • . • . • • . . • . . . • . • • • . . Backhoe . . . . . • . . . • . . • . . . . • • • . . . . . . . . . .

9-66015 9-66015 9-66015 9-66016

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9010 9033 9061 9100

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Service Manual Introduction Safety Rules /). WARNING: Operatt:! controls from the . . ope r ator's seat only. 35-; /). WARNING: Read operator' s manual to . . faromarize yourseJfwith controllevcr functions. 35-1

Whenever the loader bucket must be raised to a1d in servicing. block the bucket In place . . with 11ft cyl1nder stops or a suitable safety stand. 40-11 WARNING :

r...

WARNING : When working in the area /). of the fan belt with the engine run. . ning. avoid loose c lothing If pOSSIble . and use extreme C3'.1tion. 35-4

WARNING: Whenever cyCl1ng Ute loader or backhoe to bleec air from circuits or to check operation, be sure area Is clcnr of fellow workers. 40-12

When performtng ch ec~s A and tests on the equtpm2nt hydraultc . . system or steering systel1"., DO l'\OT devIate from the wr itten procedure. 40-13 WARNING:

General 'Ibis service manual has been prepared with the latest service information avaUable. Trouble Shooting, removal, disasse mbly. in-

spection and installation procedures coupled with complete specific ations a!ld tightening

~ WARNING : ThiS is a one man

. . no riders allowed.

machine, 3!J - t'

After Installlng tire on riro (wheel), place wheel In a saft:ty cage before inflaUng tires. If proper equIpment Is not available, ha\'e a tire repair shop do the work. 40-5 WARNING:

Some components of this machine are very heavy. ese sulth able lifting equipment or additional . . help as Instructed in this service manuaL 40-10 CAUTION:

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referonces oan be found In most sections. Some sections will have exploded views without accompanying text due to the simpl1city of the procedure. This service manual1s one of the most Important tools available to the service technician. It is an invaluable aid in properly performing any phase of service. The terms right-band and le ft - hand as used In this manual indicate the right and left sides of the mach ine as viewed from the operator' 6 seat for proper operation of the machine or attachment. The information contained in this manual is current at the time of printing.

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Table of Contents The preceedlng pages contain a Table of

Contents wblcb 118t the Series number and title, and the sections contained in each series. The individual sections, where required. will have a Table of Contents on the second page

Torque References Essentially two grades of fasteners (bolts, nuts and screws) are used on Case machinery. They a...~ grade 5 and grade 8. Refer to Section 1051 for torque specifications and means of Identification.

of that section. Page Numbers All page numbers consist of two sets of digits separated by a daSh, such as 4002-9. The digits preceeding the daSh identify the section. The digits following the dasb represent the conaecutive page mllnber within that section. Page numbers will be found at the upper right or left of each page.

Text If this manual covers more than one machine, or different models of component parts (planetary axles, gear boxes, control valves, etc.) the procedures will apply to all unless otherwise noted.

Illustrations Where possible, Ulustrations are placed as close as possible to the accompanying text and should be used as part of the text.

Serial and Model Numbers When requisitioning repair or replacement parts as it may be necessary tofurn1Sh the parts department with one or both numbers Serial and model numbers will be found in the following locations.

Machine - Plate fastened to left front cab or canopy mounting bracket. Also stamped on top of chassis behind lefthand hydraulic reservoir. Engine - Right-hand side of block below starter. COIT4>onent parts - plate attached to part or number stamped in part.

The specifications in Section 1051 are standard torque values and Should be used on all fasteners during assembly and installation unless special torque values are noted in a particular section.

Classification of Lubricants Oils, lubricants, and grease are classified and graded accordlngto standards recommended by the Society of Automotive Engineers (SAE). the American Petroleum Institute (APl), and the National Lubricating Grease Institute (NLGI).

Engine Oil The SAE number indicates the viscosity of engine oils, for example, SAE ao, a single grade oU. Engine oils are also identified by dual numbers, SAE lOWaO, a multigrade 011. The API clauification (MS DS SD CAl defines 011 performance in terms of engine usage. Only olls specified in Section 1050 should be used. These oils contain sufficient chemical additives to provide maximum engine protection. Both the SAE grade and API designation must be found on the container.

Gear Lubricant The SAE grade mlmber also indicates the viscosity of gear lubricantsdeflnedbyMIL-L -2105B. An example is SAE 90, a medlumvi8cosity lubricant.

Grease Semi- soUd lubricants specified for pivot points must be that specified in Section 1050.

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Section 1010 GENERAL ENGINE SPECIFICATIONS 580C TRACTORS THE MODEL AND EN GINE SERIAL NUMBER IS STAMPED ON A PLATE LOCATED ON THE RIGHT sIDe OF THE ENGINE BE·

lOW THE C RANKING MOTOR .

I' ~~ I@---"'I '

%( (~~

DIESEL ENGINES General Type ........ ........ ........ .. ... ........ ... .. CasE" Open Cham ber, ..J Cylinde r , ~ S t ro k ~ Cycle. Valve· in -Head Firing Order ... .... ...... ... .. ......... ...................... ... .... .... ... .......... ................... .. ................ .......... 1·3·4-2 Bo re ....... ... ", ... ... 4 Inches Stroke .......... ..... ...... ..... .. ...... ..... ... ... ... ............... .. .. ........ .. ...... ..... ....... .... ... .. .... ............. 4·1/8 Inc hes Pi ston Displacement ... ... ...... ....... ...... ............. ............. ..... .... ......... ...... .... ............ 207 Cubic Inc hes Compression Harlo .. ...... .. ........ ... ..... ..... ...... ...... .. .. ....... .... .. ........ ... .... ... .. ,......... ... ... ..... 16 .5 to 1 t\o Load Governed Speed ..... .. ...... ... .... ...... ... ........... .. ....... ..... .... .... ... ........ .... .... 2230 to 2:170 R PM Rated Engine Speed ....... .. ....... ... .. ......... ... .. ..... ....... .. .. .. ..... ........... ................. ........ ....... . 2100 RPM Engine Id ling Spc'cd ......... ..... ......... ... .. .. .. .... .. ................. ..... ....... .. ............. ... ...... 700 to 750 RPM · Valv e TappE't Clea rance I£xhaust) ..................... ............ .. .. .......... .... ... (Hot a nd COld) ,014 Inch (Intake) ...... ... ..... ..... ... .... ....... .. ........ ......... ....... ( Hot and Cold ) .012 l nch -Hot Settir!g!> AN' Made After the E ngine Ha s Operated At The rmostat Controlled Tem perature For At Least Fifteen Minutes. n

... ...... . . .... . . ...

. .. .... .

. ..

.... .. . .. .

. . .. .. . . . . . .. .. ... ...... .. . . . . . . . . . . ... . . . . . . . . . . ... . .. ... .

. .... .

Piston and Connecting Rods R ings per Pis ton ..................... ........... ,...... .. .... ...................... . ............. ... ........ ... ...... ... ..... ..... .. .... 3 Number of Com pression Rings .. ................. ... ........... .... ......... ...... ........ .......... ........... .................. . 2 Num berof Oil Rings ......... ......... .. ...... ........ ........ .. ..... ... ... .............. .... ..... .. .... .. .. ......... ........ .. ......... 1 Type PillS ....... ..... .... .... ... ......... ................ ... ........ .................. ........................... Full Floating Type Type Bearing .... ... ... . Replacea ble Precision. Steel Ba c k . Copper·Lead or Alumi num Alloy Liners

Main Bearings Number of Bearings ................... .. ...... .. ... ... .. .... ................... .. .. ... ........... ..... .... ......... .. ........... ........ 5 Type Bea rings .... ... ... Replaceable P recision Steel Back. Cop per·Lead or Alum inum Alloy Li ners

Engine Lubricating System Crankcase Capacity (Without Filter) ............ ... ... ..... ...... ..... .................................. ........... 6 Quarts ( With Filler Cha ng(' ) .... ......... ........ ..... ... ................ .................... ... .. . 7 Qua rts Oi l P ressure ..... .. ... ... 50 to 70 P ou nds with Engine Warm a.nd Operating at R atoo F. ng in£> Speed 1'ypI? System ...... .. ..................................... .. ... .. . ... ...... .. ...... ,... ..... Pressure and Spray Circulation Oil Pump ....... .. ....... ....... ... .......... ....... .... .. ..................... ............. ................................ ... Gear Type Oil Filter ..... ... .......... ... .... ...... .... ...... .... .. ... .... ..... ........ ..... ........... ........... ... Full F lnw Spir, on Type

Fuel System Fuel In je-ction Pump ...... .............. .. ........... ...... ... .. .. ............... .... ... ............. ... ....... .... Roosa· Mas ter P ump Timing .. .... ... .. .... ... ... ..... ... ... .. .... .... ... .... ......... .. ............ . 8 Degrees Before Top Dead Center Fuel [njec tors ................ .. .. ... .. ...... .. ............. .... ..... .. ...... Pencil Type (Opening Pressure 2800 PSI) Fuel Trans rer Pump ... ............... .. ....................... .. ... Vane TypP, Inlegr;)1 Part of In jection Pump Gove rnor ....... .. ... Vilfiable Speed, F ly· Weight Centrifuga l Ty pe . In tegral Part of Injection Pump Fuel F iJters ................................................ ......... ......... ...... .. ...... .. ..... Full Flow Spin on Type

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'Nus ...

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Section

1026 DETAILED SPECIFICATIONS 207 Diesel Engines

FRACTION to OECIMALto MILLIMETER CONVERSION TABLE fraction 1 / 64

1/32 3 / 64 1 / 16

5 / 64 3/32 7 / 64 1/ 8 9 / 64 5 / 32 11 / 64 3 / 16

13/ 84

7 / 32 15/ 64

1/ , 17 / 54 9 / 32 19 / 54 5 / 16 21 / 54 11 /3 2

Decimal

.0156 .0312 .0468 .0625

.0781 .0937 ,1093

.1250 .1 406 . 1562

MM 0 .397

Fraction Decimal .3593 23 / 64

0 .794 1.191

3/8 26 / 64

9.128

.3750 . 3906

9.525 9.922

.4062

10.319 10.716 11.113

, .587 1.984 2.381

13/ 32 27/ 64 7 / 16

.4376

2 . 778

29/ 64

. 4531

3 . 175 3.572 3 .969 4 .366

15/ 32 31 / 64

.4687 .4843

'1.509 11.906 12.303

1/ '

.5000

12. 700

.1718 .1875 .2031 .2187 .2343

5 .159 5 .556 5.953

.2500 . 2655 .2 B12 .296B .3 125 . 3281 . 3437

6.350 5 .747 7 .144 7.541 7.937 8 .334 8 .731

4 .762

33 / 64 17 / 32 35 / 64 9 / 16

37 / 64 19 / 32

39 / 64

5/ 8 41 / 64 21 / 32 43 / 64 11 / 16

.4218

.5166

13.097

.5312 .5468 .5625 .5781 .6937 .6093

13.494 13.890 14.287 14.684 16.081 15.478

.6250 . 6406 . 6562 . 6718 .6875

15.875 16 .272 16 .669 17.065 , 7 .462

Fraction Decimal .7031 45 / 64 .7187 23/32

MM 17. 859 19. 266

47 / 64

.7343

18.653

3/'

.7500 .7656 .7812 .7968 . SUS .8281 . 8437 . 8593

19.050

21 .431 21,828

.8750 . 8906 .9062 .9218 .9375 . 9531 .9687 .9843

22.225 22 .622 23 .019 23.415 23 . 812 24.209 24.606 26.003

1 . 0000

25.400

49 / 64 25/32 61 / 64 13 / 16

53/64 27 / 32

55/64

7/ 8 67 / 64 29 / 32 59/ 64 16/16 61 / 64 31 / 32 63 / 64

19.447

19. B44 20.240 20. 637

21 .034

INCH to MILLIMETER CONVERSION TABLE

, 2 3 ,

Inch

MM 25.400 5 0. 800 76 .200 101 .600 127. 000

Inch

, 52 .000 177. 800 203 .200 228 .600 254.000

10 20 30 40 50

•7

J I Case

MM 254.000 508.000 762.000 , .016.000 1 , 270.000

Rae. 9·78686

Inch

60 70 80 90 100

1.524 .000 1.778.000 2 ,032.000 2,286.000 2.540.000 ........ ED IN \I.s. ..

A Tenneco C omOa~ y

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1026-2

TABLE OF CONTENTS RUN Â·l N INSTRUCfIONS ................ ........................... ........ ........ ... ....... ... .... ...... ...... .......... .. ...... 3,':1 DETAILED ENGINE SPECIFICATIONS ................................................................................ 5-10 Cylinder Sleeves ....... ..... ........ ... .. .... ............ ........... ..... ..................... .. ............. ........ .................. 5 Pi slon ............. .... ... ...... .......... ............. ... ..................................... ........ ......... ............. ............... 5 Pis ton Rings .... ........ ......... ...... ...... ......................................................... .......... ............ ... ..... .. 5.6 Piston Pin ..... .. ..... .......................... .................................................................................. ...... . 6 Connecting Rod .............. ... .. ........... ................................................................................... .. ..... 6 Crankshaft ...................... ...... ........ .......... .............................................................................. 6,7 Camshaft ..... ........... ... ........... .... .. .......................................................................... ........ ............ 7 ValvE' Push Rod Lifters ................. .... ........ ............................... ......... ............................. .... .... 7

Gear Train ............................................................................................................................... 8 011 Pump ....... ..... ... ..... ... ..... .............................. ................................ ........... ........... ........ .. ........ 8

Cyllnder Head ....... ............................ ....... .......... ..... ............ ... .............. ..................... .............. 8 Intake Valve ........... ....... ...... ... ............... .......... .................. .................... ......................... .......... 8 Exhaust Valve ......... ........ ...... .... ............ ................... ....................... .... .......... .......... ....... ..... .... 9 Intake and Exhaust Valve Guides ............................................................................................ 9 Valve Spring ............................................................................................................................ 9 Rocker Arm Assembly ............................................................................................................ 10

SPECIAL TORQUES . ....... .......... ..... ..... ........... .......... ................ ............ .... ............... .................. 10 GENERAL TORQUE SPECIFICATION TABLE ........................................................................ 11

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1026-3

RUN-IN-INSTRUCTIONS Engine Lubrication When tile engine rebuild is complete, fi ll the engine crankcase with Case HOM oil and install new engine oil filter. NOTE: If Case HDM oil Is not used, use only a Series 3 DS or CD Service GassIfication oll thaI has Ihe proper viscosity ra ting for prevailing air temperature. Refer to vehicle Operator'S Manual. Alter the first 20 hours of operation, change the engine oil while the engine is hot and re place the engine oil filter. DO NOT DRAIN OIL UNTIL THE ENGINE HAS BEEN OPERATED 20 HOURS.

Change the engine oil and filter at the recommended intervals thereafter as outlined in the Opera· lor's Manual.

Break-In Procedure for Rebuilt Engines (With a Dynamometer) The following procedure must be implemented when using a PTO dynamometer to break-in tbe engine. The dynamometer will insure control of the engine load a l each speed and will eliminate over stressing new parts during break·in.

During the break·in, continually check the 011 pressure, coolant level, and coolant temperature. STEP I

3 4 5 6

TIME

ENGINE SPEED

'·10 Minutes 100.1 RPM "10 Minutes 1800 RPM

DYNAMOMETER SCALE LOAD-

None None

20 Minutes 1800 RPM 1/3 IJ2 20 Minutes 1800 RPM .0° 30 Minutes 100 RPM below rated speed 3/. Retorque the cylinder head bolts using the procedure described In Section 2015 of this service manual. °Based upon normal dy namometer scale load at rated speed for the particular vehicle

model. Reduce this scale load as indicated. "The most ideal break·in procedure would be to constantly vary the throttle between 750 to 1000 RPM for the first 10 minutes and from 1000 RPM to 1800 RPM for the next 10 minutes. Tile purpose of this changing RPM is to vary the lubrication and coolant flow. '0'30 minutes at 3/ 4 load is a minimum amount of time the engine s hould be run. It is

recommended that whenever possible the engine (especially turbocharged diesels ) should be run for four (4) hours or more at the above speed and load before checking the full engine horsepower or before using the engine for heavy field work.

Break-In Procedure for Rebuilt Engines (Without a Dynamometer) STEP 1

2 3

• 5

ENGINE SPEED LOAD 1000 RPM None 1800 RPM None 30 Minutes 213 Rated RPM Light Load 1 Hour Full RPM i not over 2000 RPM) 80 to 9O'li• Retorque the cyUnder head bolts using the procedure described in Section 2015 of thts service manual.

TIME °10 Minutes ' 10 Minutes

'If engine must then ru n a t or near full load to operate the machine - for first hour

remove load and run at high idle for a few minutes at 15 minute intervals.

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1026-4

RunÂˇ'n Procedure (Agricultural Tractors) For the first 8 hours of field operation stay one gear lower than normal For the Dext 12 hours DO NOT "lug" the engine. Prevent "lugging" by shifting to a lower gear. The engine must not be "lugged" below Its Rated Engine RPM during the early hours of Hfe.

Run-In Procedure (Construction Equipment) For the first 8 hours, operate the engine at full throttle maintaining a normal load. DO NOT baby the engine, but avoid prolonged converter or hydraulic stall. Engine must not be "lugged" below its Rated Engine RPM (00 not exceed 10 seconds of stall).

Run-In Procedure (Power Units) For the first 112 hour. operate engine at 2/3 rated RPM with a light load or no load. For the next (1) hour, run engine at 80 to 90% load at rated RPM (but not over 2000 RPM). Then full load and rated RPM as reQuired In application.

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1026-5

DETAILED ENGINE SPECIFICATIONS Cylinder Sleeves Type

U,S. Value

Metric Value

........ ............ ..................................... Replaceable. Wet

Material ....... ... ... .... ...... ................... .. ...... ....... .. Chrome Plated Steel

sleeve ......... ....... .......... .. .. .. ............. .. .............. 4.000 to 4.0010" Maximum Serviceable Limit ... ........ ........... ....... ... .... ........ . 4.0020"

101.600 to 101.625mm

Sleeve out-of-round (Installed in block) .. ..... ........ .. ............. 001" max.

.025nun max.

Taper (Installed In block) ............... .......... .. ... ..... ... ... ......... 002" max. to piston pin .... 00:10 to .0060"

.05lmm max. .102 to .152mm

Maximum Serviceable Limit .... .. ...... .......... ....... ... ,.. ............ ... 0080"

.203mm

I.D.

Clearance to bottom of piston skirt,

9()0

101.65lmm

Piston Type ............... ... .... ............ ............................................ Cam ground

Material ......... ...... ........... ....... ............................ .. .... Aluminum Alloy 0.0. at bottom of s kirt. 9QO to piston pin ........ .. ... ...... 3.9950 to 3.9960"

101.473 to l01.498mm

Minimum Se:r.Âˇlcea ble Limit ............ .. ... .......... ......... .... ........ 3.99010"

lOl.44Hmm

I.D. of piston pin bore including wear ...................... 1.2500 to 1.2508"

31.750 to 31.770mm

Width of 1st ring groove .. ..................... ..... ... ...... ....... Keystone Type Width of 2nd ring groove ........... ....... ........... ....................097 to .098"

2.464 to 2.489mm

Maximum Serviceable Limit ..................... ...... ........ ........... ..... 100"

2.540mm

Width of 3rd ring groove .... ........ .................................. 1885 to .1895"

4.788 to 4.813mm

Maximu m Serviceable Limit ........... ...................................... .1915"

4.8S4.mm

Piston Rings No. 1 Compression ...... ........ .. ... .... .............. ... .. Moly Faced Keys tone End gap in 4.000 1.0. (101.600mm 1.0.) sleeve .... ... ...... 015 to .025"

.381 to .635mm

Maximum Serviceable Limit ......... .... ...... .................. ...... ..... .035"

.889mm

Width .. .. .. ........ .... ........ .. ..... ... ..... ........... ...... .... ..... .. Not Measurable Side Clearance .. ......... .. ...... .. ........ ..... .. ......... ... ...... Not Measurable NO. 2 Compression ......... ..... ...... .. ... .. .. ..... Rectangular Grooved Back End gap in 4.000 1.0. (lOl.600mm 1.0.) sleeve .. ....... .. ..013 to .023'" Maximum Serviceable Limit ...... .. .. .................................. .... .033"

.330 10 .584mm .838mrn

Side clearance ...... ... ..................................................0035 to .0050"

.089 to .127mm

Maximum Serviceable Limit ............. ...... ......... .. .. .. .... .......... .008"

.203mm

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102...

Piston Rings (Cont'd.)

U.S. Value

Metric Value

No. 3 011 Control Ring ...................... ... ................ .. ..... ... ... Two Piece End gap in 4.000 I.D. (lOl.600mm 1.0.) sleeve ,............013 to .023"

.330 to .584mm

Maximum Serviceable Untit .................................................033"

.838~

Side clearance ............ .. .............................................0020 to .0035"

.051 to .089mm

Maximum Serviceable Limit .. ............................................ ...005"

.127mm

Piston Pin Type .............................................................................. Full Floating . ...........................•.......... 1.2495 to 1.2498"

31.737 to 31.745mm

Fil In piston .................................................................. 0002 to .OUO"

.0f6 to .025mm

Fit In rod bushlDg ..................................................... . .0004 to .0015"

.010 to .038mm

0.0. of pin ............. .

Connecting Rod Bushing ............. ....... ......... ....... ........ ................... Replaceable Bronze

Bushing I.D. installed (ream to size) ....................... 1.2502 to 1.2504"

31.755 to 31.760mm

Maximum Serviceable Umlt ........................... .. ........ ... .. ...... 1.2510"

31.775mm

Bearing liners ................................................................. Replaceable Journal LD. without bearing liners .......................... 2.4002 to 2.4007"

60.965 to GO.978mm

Bearing oil clearance ....... ...... ...... .. ........ .......... ............. 0010 to .0040"

.025 to .102mm

Undersize bearings tor service ................................002,.010,.020,.030"

.051..254,.508,.762mm

Side clearance ... .. ........................................................... 005 to .011"

.127 to .279mm

Crankshaft Type .. .... ......... .. ..... ....... .. ........................... Hardened Steel Balanced

Main bearing liners ... ... ................. ................................. Replaceable

End play, center main bearing cap ... ......... .................... .001 to .015"

.025 to .38lmm

Center main bearing thrust surface thickness ....... 1025 to .1045"

2.600 to 2.654.nun

Connecting rod journal std. 0.0 ............................... 2.2480 to 2.2490"

57.099 to 57.125rnm

.002" ( .05lmm ) 0.0. ufldersize, grind to ....... ....... 2.2460 to 2.2470"

57.048 to 57.074mm

.010" (.254mmJ 0.0. undersize, grind to ................ 2.2380 to 2.2390"

56.845 to 56.871mm

.020" (.508mm ) 0.0. undersize, grind to ................ 2.2280 to 2.2290"

56.591 to 56.6limm

.030" (.762mml 0.0. undersize, grind to ................ 2.2180 to 2.2190" Connecting rod journal maximum taper ..................................... 001" Jourflals out·ot·round ................ ...... ........................ ....... ............ 0CI05"

56.337 10 56.363mm .025mm

Undersize main bearing liners for service .............. 002,.010,.020,.030"

.051,.2501., .508,. 762mm

Main bearing oil clearance ....... ........ ......... ..................0012 to .0042"

.031 to .107mm

.013mm

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1026-7

Crankshaft (Cont'd,)

U.S. Value

Metric Value

Main bearing journal std . 0.0 ........ ...... ................... 2.8730 to 2.8740"

72.974 to 73.00Jmm

.002" (.051rnm) 0.0. undersize, grind to ................ 2.8710 to 2.8720"

72.923 to 72 .949mm

.010" (.2.'>4mm) a.D. underSize, grind to ..... ....... .... 2.8630 to 2.8640" .020w (.508mm) O.D. undersize, grind 10 ................ 2.8530 to 2.8540"

72.720 to 72.746mm

7'lAGS to 72.492rnm

.030" (.762mm) 0.0. undersize , grind to ................ 2.8430 to 2.8440"

72.212 to 72.238mm

Main bearing journlll bore 1.D. without liners _______ ... ... 3.066 to 3.067"

77.876 to 77.902mm

Main journal width between cbeeks:

2nd&4th .... ... ..... ........... ...... ................... .... .

. ... 1.185 to 1 .189"

30.009 to 3O,201mm

to 34.976mm

:lrd ... ....... .. ............ ..... ..............•. .......... .. ...•. ....... ....... 1.374 to 1.377"

34.!:()()

5th ............. ... ....... ...... ..... ......... .,....... .... .... ............... 1.745 to 1.755"

44.323 to 44.5nmm

Connecting rod journals width between cheeks ......... 1.3105 to 1.3145"

33.287 to 33,388mm

Camshaft Type ................ . ......................................... Hardened lron Parabolic Bushlrlgs Bushing

....... ................................................ 5, Replaceable l~ubricat!on:

Front Bushing .......................... .. ...................... Pressure lubricated from oil pump. Intermediate Bushing ...... ........ .... .... .......... Gravity Flow lubricated Rear Bushing

Pressure lubricated with rear oil metering.

Oil clearance ............ ...................................................... 002 to .007"

.051 to .l78mm

LD. of bushing Installed .............................................. 1.752 to 1.753"

44.501 to 44.526mm

Ma;(.lmwn Serviceable LiInit ....... ............................ ......

1.755"

44.5TImm

..... .. ........ ..... ................................ 1.213 to 1.223"'

30.810 to 31.064mm

2nd, 3rd and 4th ....... .................................................... 490 to .:;00"

12.446 to 12.700mm

5th (rear) ... .. ... . ....................................................... 1.213 to 1.223"

30.810 to 31.D64mm

O.D. of each b£'arlng surface ................................ ....... 1.749 to 1.750"

44.425 to 44A50mm

Minimum Serv iceable Limit ................................................ .. 1.748"

44.399mm

Thrust washer thickness .................. ...... ......... .. .. .... ........ .147 to .149"

3.734 to 3.785mm

Bushing width: 1st (front)

Minimum Serviceable Limit ............. ..... ..... Maintain end clearance Camshaft end play

......... .................... Taken up by thrust washer

Camshaft end clearance .................................................. 003 to .007"

.076 to .178mm

Valve Push Rod Lifters Matenal .......... .. ...... ........... ....... ............ .. ................ .. Hardened Steel .... ..... . __ . ... ... .. ...... .. ............................... .................... Mushroom .5605 to .5610"

14.237 to 14.249mm

LD. of block bOre, including wear ............... . .............. .. 5625 to .5650"

14.287 to 14.351mm

O.D. of lifter stem ..... ....... ......... .... ....... ....... .... ........ ..

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10""

Gear Train

U.S. Value

Metric Value

.!XlO2 to .006"

.005 to .IS2mm

Camshaft gear to Idler gear ...... ....... ......... .................0004 to .006"

.010 to .152mm

Idler gear to fuel pump gear ... ........... ..... ........... ........0005 to .007"

.013 10 .178mm

Crankshaft gear to 011 pump gear .............................. . .002 to .008"

.051 10 .203mm

Crankshaft gear to fuel pump gear ...................... ... .... 0005 to .019"

.013 to .483mm

0.0. of idler gear shaft ............. ......... ...................... 1.3745 to 1.3755"

34.912 to 34.938mm

MinlmUJll Serviceable Limit ....... .............................. ............ 1.3740"

34.900mm

J.D. of Idler gear with bushing ........................... ... ...... 1.376 to 1.377"

34.950 to 34.976mm

Maximum Serviceable Limit ...... ........................................... 1.377"

34.9i6mm

..... .. ............. ....... 005 .. 006,.007 •.009"

.127,.152,.]78, .229mm

................................... .. ........................ .1))3"

.075mm

Backlash: Crankshaft gear 10 camshaft gear

Idler gear thrust washer shims Idler gear end play

Oil Pump Positive displacement pump ..... ........................................ Gear Type Backlash, pump gear 10 crankshaft gear ........ ........ ........ 002 to .008"

.051 to .203mm

Drive gear to pump body maximum clearance ..... .. .... . . 0035 to .010"

.089 to .254mm

Pump gears to body radial maximum clearance

.002 10 .008"

.051 to .203mm

Pump gears to pump cover maximum clearance

.OC115 to .008"

.038 to .203mm

to 70 PSI

344.74 to 482.63 kPa

Free length ........................................ ................................... 2.125"

53.975mm

Compressed 1.44" (36.58mm ) ....................................... 18 to 19 Ibs.

8.]6 to 8.62 kg

Oil pressure

................................................................... 5(1

Relief valve spring:

Cylinder Head Warpage .......

... ................................................. 006" max.

.152mm max.

Intake Valve Tappet clearance (COLD and HOT)

...........................................012"

.305mm

Face angle .... ............. .............. ........................ .......................... ... 44° Face run-out ......................... ..... ........................................ 002" max.

.05lmm max.

Length ...................... ......... .......... ................................ 6.339 to 6.364"

]6l.0Il to 161.646mm

0.0. of stem ..... ........................................................ .. .3409 to .3419"

8.659 to 8.684mm

Minimum Serviceable Limit ............. ......................................3399"

8.634mm

0.0. of head ............ .... ............................................... 1.599 to 1.609'"

40.615 to 40.869mm

Seat angle .............................................. ... ... ................................. 45 G

45'

Seat contact width ......... .... ....................................... .... 0704 to .1057"

1.788 to 2.685mm

Seat run·out .......... .... ....................................................... .002" max.

.05lmm max.

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1026-9

Exhaust Valve u.s. Value Tappet clearance (HOT and COLD) .•...........•........... ............. .... . OU" Face angle ............................................ .......................... .. ...... .... .. 44°

Metric Value

Face run·out ............................ .............. ..... ............... ... .....002" max.

.051mm max.

0.0. of head ....................... ........ .......... .. ..... .... ............ 1.398 to 1.408'"

35.509 to 35.763mm

8.634 to 8.659mm

Minimum Serviceable Limit .......... .. ....... ... . ................ ......... ...3389~

8.6a!mm

0.0. of stem ........................... .... .................. . ..... .......... 3399 to .3409 Length ...... ..................................... ............. ...... ........... 6.340 to 6.364

...

.356mm

...

161.036 to 161.646mm

Insert seat a ngle ........ ......... ...... ............. .............. ...... .. .......... ....... 45' seat contact ""Idth ..... ...... ...................... ..... .......... ........ 0608 to .0962" Seat run·out ............... ........................ .... ... .... ........ ........ .....002" max.

1.544 to 2.443mm .051m.m max.

Insert height ..... ........ ..... .. ......... .... ............................. ... 2475 to .2525"

6.286 to 6.413mm

1.4~'"

36.817 to 3G.843mm

1. 0. of insert ........ ................... ......... .... ........ .... .... .. .. .. . 1.245 to 1.255-

31.623 to 31.877mm

0.0. of insert .. ... ..... ............ ....................... .... ........... 1.4495 to

Intake Valve Guides Length ..... ... ............ ... .......... ... ............ ........ .......... .... ......... ...... 3.250" 0.0 . ... .......... ....................... .......................................... 6565 to .65751.0. (Installed and reamed) .......... .... ........ .... ...... .........3429 to .3439'"

82.55Omm 16.675 to 16.700mm a.no to 8.735mm

Maximum Serviceable limit .................................................. 3449 ~

8.76Omm

Protrusion above cylinde r head ....... ,............ . ............................. 875" Valve stem cleara nce in guide ................. ........ .............. JlOl to .003"

22.225mm .025 to .076mm

MaximUm Serviceable limit ................................................... 004"

.102mm

Exhaust Valve Guides Length ......... .. ............ ... ... ........... ... ........................... ............... 3.125"

79.375mm

0.0 ... .. ..... ....... ... ................. .... ...... ............ ........ ........... .6.565 to .6575"

16.675 to 16.702mm

to.

(Installed and rea med) .. .. ........... ........................ ... 3429 to .3439'"

8.no

8.73Smm

Maximum Serviceable limit ... ............................................... 3449"

8.761mm

Protrusion above cylinder head .... ... .......... .. .. ... .... ... ...... ............ .875"'

22.225mm

Valve

stem clearance

In guide .. ................. .. .................. .002 to .004"

.051 to .102mm

Maximum Serviceable Lim it .. ............ .. ... ....... .. .. ......................005"

.121mm

Valve Spring Free lengt h ........ .............. ................ ....... _..................... ... ........ 2.375"'

6O.325mm

TOlal coilS ....................... ........ ..... ............................. .............. ... 8.25

\Vlre diameter ................. ........... .. ... ..... ........... ..... ...................... 162"

U15mm

J.D.... .................................................. ............ .... ... .......... 958 to .978"

24.333 to 24.B41mm

Compressed 10 1.52r (38.633m m) (valve open) ...... 110 to 118 Ibs.

49.90 to 53.52 kg.

l b~.

24 .04 to 26.76 k&:.

Compressed 10 1.875"' f47.62:imm)

(valve closed) .... 53 to 59

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1,026·10

Rocker Arm Assembly

U.S. Value

Metric Value

0. 0. of shaft ........ ......................... ...... .... .... ......... ....... .. . .622 to .623" 1.0. of arm bore ....................... .................................... . .621 to .626" Shaft spring : Free length ....................... .. .......................................... ....... .... 2.5"

15.799 to 15.824mm

Compressed to 1.75" \44.450m m) ............................... 7.5 to 8.5 Ibs.

3.«1 to 3.86 kg.

15.850 to lS.900mm

63.500mm

Lubrication .... . ..... .... .......... ... ............. Engine 011, camshaft metering Shaft oil holes ............... .. .................... Toward valve side of engine. Shaft cannot be rota ted.

SPECIAL TORQUES Engine Camshaft nut

. .... . ....... . . . ... . ..... . .. . ...... ....... ......~m% f '~

109 to 122 Nm

Camshaft thrus t plate mtg. bolts ........................ .. ..... 17 to 20 ft. Ibs .

23 to 27 Nm

Connectlng rod nuts ........................................ .......... 45 to 50 ft . Ibs.

61 to 68 Nm

Crankshaft main bearing bolts ... .............................. 90 to 100 f t. Ibs.

122 to 136 Nm

CrankShaft pulley nut .............. .. .......... ..... .............. 125 to 135 ft . Ibs.

169 to 1&3 Nm

Cylinder head bolts fGr. 8,12 pt. hd.) ..................... 105 to 115 it. Ibs . Cylinder head stud nuts (1/2") .. ... ............. .. ...... ...... 95 to 105 ft. Ibs.

122 to 137 Nm

129 to 142 Nm

Cylinder head valve cover stud (3/8") ...................... 35 to 42 ft . Ibs.

48 to 57 Nm

Cylinder head valve cover stud (112") ............... .. ..... 80 to 96 ft . Ibs.

l OS to 130 Nm

Cyllnder'head v alve cover st ud nuts (3/8") ............... .. . 4 to 6 ft. Ibs.

5 to 8 Nm

Engine oil filter ..... .. ..... . ...... ..... ... Install until gasket contacts filter head , then hand tighten 112 turn. Loosen filter approximately one full turn and retighten until gasket contact is made, then hand tlg· hten an additional 112 to 3/ 4 turn. Exhaust manifold stud nut .... .. ........... .................... .. 25 to 30 ft. Ibs.

34 to 41 N m

Fan mounting bolts ......... .... ....................................... 17 to 20 ft . Jbs.

23 10 27 N m

Flyw heel to crankshaft bol ts ...... ........ . ...... ......... .. .. .. 65 to 70 ft. lbs.

88 to 95 Nm

Fuel pump drive gear nul ... .... .................. .. .............. 40 to 50 fl . lbs.

54 to 68 Nm

Idler gear journal mounting bolts .... .... ............ .......... 35 to 42 tl. lbs.

47 to 57 Nm

Intake manUold SlUe!

30 to 35 fl. Ibs.

41 10 48 Nm

011 pan capscrews (stamped steel) ............................ 10 to 12 ft. lbs.

14 to 16 Nm

Oil pan dra in plug ......... .. . .. ...................................... 29 to 31 ft. Ibs. .. .... ............... .... ........ ...... 15 to 20 It. Ibs.

39 to 42 Nm 20 to 2, Nm

011 pump cover capscrews .. ..... ..... .... .............. .. ........ .. 9 to 11 tt. lbs.

12 to 15 Nm

!lU i

011 pan to seal retainer.

.... .. ..... . ... . ...........................

011 pump s uction lube nut .. ........ ...... ...... .................. 95 to l OS fl. Ibs.

129

OU seal retainer bOlts ........ .. .............................. ........ 12 to 15 ft. lbs.

142 Nm 16 to 20 Nm

Rocker arm bracket bolts .. .......................... ....... .. ..... 25 to 30 ft. Jbs.

34 to 41 Nm

Timing gear co\'cr mounting bollS ............................. 25 to 30 ft. Ibs.

34 to 41 Nm

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48 to 57 Nm

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1026-11

GENERAL TORQUE SPECIFICATION TABLE

IRevi.ed 2 -741

U SE TH E fOLLOWIN G TOROUES WHEN SPECIAL TO RQUES ARE NOT GI VEN S<rn!: : TI>csc "'lIOn aWl)' !o f~$l"""'" u ...(... " ..... from .uppU.. r, dr}'. Of' " 'IIP" lub<lÂ· C~!ed

wUh norma l .... glM 0 11 . Th<')' do not

lI .... au,$ or 01h('r

1!'~!~1T1l'

prt'SSur..

~ppl)

lu brk:~n ts

II specu l

~ra l'h Uo:'d

ar .. uU-'d This

~pplln

o r mol) '<I!$wlplll(k,

!o both USF

~1Id

U,.C !hn!adJ.

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Section

1050 MAINTENANCE AND LUBRICATION

J I Case A Tenneco Comparly

E. Dlv. 9-66015 ....."'" ... u.s. ....

February 1976

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1050-2

FLUIDS AND LUBRICANTS COMPONENTS Fuel tank

CAPACITY Metrlc U.S. 22 gallons

83 lIters

Engine crankcase Without filter change

6 quarts

5.7 liters

With filter change

7 quarts

6.S liters

Hydraulic system (approx.) Loader/backhoe Loader only Loader/tnree point bitch Reservoir refill

SPECIFICATIONS Refer to Operator's Manual. Case HDM 011 Engine oU, class CD, Above 32° F (0' C) . . . . . • . SAE 30 10' -50' F (-12"-10· C) ••. SAE 20W Below 32" F (0" C) •••••• SAE lOW Case TCR Fluid

30 gallons 21 gallons

113 liters 79 liters

Alternate oil EngIne oU, SD or CA

25 gallons 17 gallons

94 liters 64 liters

Power shuttle and converter

8 quarts

7.6 Hters

Case TCH Fluid.

Power steering system Reservoir refill

3 quarts 1 quart

2.8 Itters 0.9 liter

Case TCH Fluid.

Mechanical shuttle

2 quarts

1.9 liters

Case TCH Fluid.

Transaxle

20 quarts

19 liters

Case FDL gear lubricant or lubricant meeting API-GL-4, specification Above 0" F (-18' C) . . . . • . SAE 90 Below 0" F (-IS" C) .•.••• SAE 80

Above 32" F (0' C) • • . • SAB lOW Below 32" F (0' C) •••.• SAE 5W Type C-2 transmission/hydraulic fluid suCh as Tenneco Hytrans Fluid.

Grease fittings

As required

No. 2 moly disulfide grease.

Front wheel bearings

As required

No.2 moly disulfide grease.

Cooling system

21 quarts

19.8 liters

Mix ethylene glycol type antifreeze and water for lowest anticipated temperature.

Battery

As required

Add colorless, odorless drinking water.

Brake master cylinders

As required

DOT 3 brake fluid.

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1050-3

MAINTENANCE CHART NOTa: This chart is based on maximum service Intervals. If operatlng in severe working conditions, servIce more often.

INTERVAL

SERVICE

Run-In perIod. Every t\IIo hours until stable

Torque front and nar v.1:leel bolts to 115-130 foot-pounds (157-176 N m).

INSTRUCTIONS

Torque transaxle mounting bolts to 250-300 foot-pounds (339-407 N m) . Torque swing cylinder trunnIon plate mounting bolts to 520-640 foot-pounds (732-867 N m) . Torque drive shaft cap screws to 20-24 footpounds (27 -32 N m) . Run-in perIod after first 20 hours

Every 10 hours of operation or daUy, whichever occurs first

Change engine oU and filter. Change hydraulic oil filter.

Section 4002

Check fan belt tension.

Section 8007

Grease loader pivot points. Grease backhoe pivot points. Grease extendable dipper, if so equipped. Grease thne point hitch, if so equtpped. Grease front axle pivot. Grease front axle king pins. Grease power shuttle bellcrank. Check engine 011 level. Check hydraulic oU level. Check radJator coolant level. Clean air cleaner dust cup.

Section 2051

Check power shuttle all level (if so equipped).

Section 6202

Cbeck the machlne and the ground under it for signs of leaks. Check injection pump sediment bowl for water. If bowl has water, drain fuel tank, first stage fuel fUter and sediment bowl.

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1050-4

rnTERVAL

SERVICE

Every 100 bours of operation

Change engine oil.

rnSTRUCTIONS

Grease rear axle bearings. Grease seat post. Grease brake pedals and Shaft bearings on power shuttle machines. Greas e brake pedals and clutch shaft on mechanical shuttle machines. Check tire condition and pressure.

Section 6229

Check battery fluid level.

Section 8005

Check transaxle oll level. Check mechanical shuttle oil level. Check power steering oU level.

Every 200 bours of operation Every 500 hours of operation

Clean spark arresting muffler if so equipped.

Section 2051

Change engine 011 filter.

Section 2555

Check fan belt tension.

Section 8007

Grease universal joints. Lubricate hydraulic pump shaft.

Section 4005

Replace fuel filters.

Section 3010

Check brake master cylinder fluid level.

Every 1000 hour s of operation or once a year, whichever occurs first

Repack front wheel bearings.

Section 5021

Inspect Roll-Over Protection Structure.

Section 9061

Change hydraulic oil filter.

Section 4002

Clean hydraulic reservoir breather.

Section 4002

Change hydraulic oll.

Section 4002

Change power shuttle oil, if so equipped.

Section 6202

Replace power steering 011 filter,

Section 5005

Change mechanical shuttle oil, If

equipped.

Change transaxle 011. Clean transaxle breather.

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1050-5 INTER VAL

SE RVICE

INSTRUC TIONS

Every 2000 hours of operation or once a year . whichever occurs fir st

Drain, flush and refill cooling system.

Section 2050

As required

After a Wheel has been removed and installed , check bolt torque every tvlo hours until stable. Service air filter element whenever restrIc tion warning light remains on with engine running at full throttle .

Se.ction 2051

Change hydraulic oil filter whenever res triction warning light remains lit.

Section 4002

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Section 1051 TORQUE SPECIFICATIONS

J I Case

C. E. Div. 9-66015

A1,,"""0 Comoanv

February 1976

.....11.. It< ... , ..

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1051-2

U.S. AND METRIC TORQUE SPECIFICATIONS Grade 5 Bolts, Nuts and Studs (Dry Threads) Thread size

Ft-lus

N m

Thread size

Ft-lbs

1/4"-20 NC 1/ 4"-28 NF

5-10 10-15

7-13 13-20

3/4"-10 NC 3/4"-16 NF

235-285 270-330

319-386 3-66-447

5/16"-18 NC 5/16"-24 NF

15-20 15-20

20-27 20-27

7/8"_9 NC 7/8"-14 NF

360-440 395-490

488-597 536-664

3/8"-16 NC 3/8" -24 NF

25 - 35 30-40

34-47 41-54

l"- BNC 1"-12 NF

520-640 575-705

705-867 780-955

7/1 6"-14 NC 7/1 6"-20 NF

45-55 50-60

61-14 68-81

1 -1 /8"-7 NC 1-1/8"-12 NF

720-820 790-970

976-1111 1071-1315

1/2"-13I"C 1/2" -20 NF

65-85 80-100

88-115 109-135

1-1/4"-7 NC 1-1 /4" -12 NF

1010-1240 1115-1365

1370-1681 1512 -1850

9/16"-12 NC 9/16"-18 t\F

100-120 110-130

135-163 149-176

1-3/8"-6 NC 1-3/8"-12 NF

1315-1610 1510-1850

1783-2182 2047-2508

5/8"-11 NC 5/8"-18 NY

135-165 160-200

183-223 216-271

1-1/2"-6 NC 1-1 /2" -12 NF

1745-2135 1880-2420

2366-2894 2549-3281

Grade 8 Bolts, Nuts and Studs (Dry Threads) Thread s ize

Ft-Ibs

Thread size

Ft-1bs

1/4"-20 NC 1/4"-28 NF

10-15 15-20

13-20 20-27

3/4"-10 NC 3/4"-16 NF

340-420 380-460

461-569 515-623

5/16"-18 NC 5/16"-24 NF

20-30 25-30

27-40 34-40

7/8"-9 NC 7/8"-14 NF

540-660 595-125

732-894 807 -982

3/8"-16 NC 3/8"-24 NF

40-50 45-55

54-67 61-74

1"-8 NC 1"-12" NF

810-990 900-1100

109 8-1342 1220-1491

7/16"-14 NC 7/16"-20 NF

60-80 70 - 90

82 -102 95-122

1-1/8"-7 NC 1-1/8"-12 NF

1150-1400 1295-1585

1559-1898 1756-2148

1/2"-13 NC 1/2"-20 NF

100-120 110-130

136 -162 149-116

1-1/4"-7 NC 1-1 /4"-12 NF

1640-2000 1800-2200

2224-2711 2440-2982

9/16"-12 NC 9/16"-HI NF

135-165 155-190

183-223 210-257

1-3/8"-6 NC 1-3/8"- 12 NY

2140-2620 2450-3000

2901-3552 3322-4067

5/8" -11 NC 5/8"-18 NF

200 - 240 215-265

271-325 292-359

1-1 /2" -6 NC 1-1/2"-12 NY

2845-3475 3200-3900

3857 -4711 4339-4880

® © / 1'

Figure 1

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1051-3

U.S. AND METRIC TORQUE SPECIFICATIONS Hydraulic Fittings (Steel) Dash Size

Tube 0.0. Hose I. D.

37 0 Flare Torque

Thread Size

Ft-Ibs

Straight Thread O-ring Torque

Ft-Ibs

1/ 4"

7/16"-20

6-12

8-16

12-19

16-25

5/ 16"

1/ 2"-20

8-16

11-21

16-25

22-33

â&#x20AC;¢

3/8"

9 / 16"-1 8

10-25

14-33

25-40

34-54

1/ 2"

3/ 4"-16

15-42

20-56

42-67

57-90

5 / 8"

7/ 8"-14

25-58

34-78

58-92

79-124

3/4"

1-1 / 16"-12

40-80

54-108

80-128

108-174

7/8"

,..

1 -3/ 16"-12

60-100

81-135

100-160

136-216

1-5/16"-12

75-117

102-158

117-187

159-253

1-1 / 4"

1-5/ 8"-12

125-165

169-223

165-264

224-357

1-1 / 2"

1-7/ 8"-12

210-250

285-338

250-400

339-542

I. 14

Split Flange Mounting Bolts (Grade 5, Dry Threads) Flange Size

Thread Size

Torque

Ft-lbs

1/2"

5 / 16"-18 NC

15-20

20-25

3/4"

3/8"-16 NC

20-25

26-33

3/8"-16 NC

20-25

26-33

1-1/4"

7/16"-14 NC

35-45

47-61

1-1/2"

1/2"-13 NC

45-55

61-74

1/2"-13 NC

55-65

74-88

2-1/2"

1/2"-13 NC

80-90

104-122

5/8"-11 NC

140-150

190-203

,..

"OlH

Figure 2

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Section 1052 NOISE CONTROL

J I Case

E. Dlv. 9-66015

......$..to.

A TennecoCompany

February 197 6

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1052-2

NOISE PROTECTION J I Case provides noise abatement kits that may be factory or field installed. Each kit Is made up of an acoustical foam material. This material must be kept clean and intact to maintain the proper leval of noise protection.

level. Be sure to check with local authorities to determine what the requirements are. Listed below are checks that must be performed to insure continuing noise protection.

Cleaning 1.

surface dust or dirt, hose down with water. Steam dean parts that have b3comecontamlnated with oil or graase. Squeeze out the excess water.

Check that all exterior parts and sheet metal fasteners are tight. All rattles close to the operator's area mllst be elimInated.

If the Padding is saturated with oil or grease and does not clean up. replace the contaminated part.

Check that all sealing and barrier materials are whole and Intact. A small hole can admit a large amOlUlt of noise.

Check noise isolators such as engine mounts , rubber shock mounts. hydrauliC tube isolators. etc. Replace Ii defective.

Check that the full throttle - no load engine speed is checked with an accurate tachometer. '!be engine speed must be within the limits as listed in Section 1010.

Use a brand name contact cement according to manufacturer's instructions to hold padding in place.

Check the full range of engine speed for resonance (loud, undampened vibration). To check, increase the engine speed from low idle to full throttle slowly. If excessive resonance is found. eliminate the vibration of the suspected part.

Checking Noise Protection

NOT!!:

The laws of some ciUes. states or provinces may require that your machine be checked and certified for a maximum noise

Handbook.

If the padding becomescontaminatedwU:b.

Replacement

Ht ~\'l<;:" thC' :\1', j h'~ C:PI): \' III LIlIol] h, k,n' appll' 'C:: the ~dht'''ln :;9-10

WAAN'NG:

When installing padding make sure the metal surfaces are clean of all oil, grease, excessive rust and traces of old material. It Is very Important that the new piece cover the same area as the old one.

For your general information, see the SAE recommended practice on SOlUld levels and measurements. Refer to SAE J919a, J87 and Ja8 in the SAE

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Section 2001 ENGINE DIAGNOSIS

188 and 207 Diesel Engines

J I Case

Rec. 9-78875

I'IIJoIoI'l'm IN

A TeontlCO Company

u.s.A.

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2001·' GENERAL INFORMATION Before

making

on an engine,

any

repair.

adjus1meflts

mechanic or technician mus1

properly diagnose the trouble .

Locating the trouble and repairing it is only Plrt of the job, a lectmlcian must find and eliminate the cause of the trouble 81 well. Too many repairs IrB made with no thought

to removing the causes that made the repair nec••sary. For any engine to start or perfonn property. three main requirements must be preaeot: 1 , FUEl 2 . COMPRESSION 3 . COMBUSTION

When any of these requirements ar. not present Or limited by some mechanical ,uson, the angine will not start and will fail to operate properly throughout the power range .

fUEL . Fuel system problems can be present anywhere from the fuel tank, through the filter. and injection pump as wen as the injectors. Correct injection pump timing il important in the overall fuel system performance.

COMPRESSiON. Compression on an engine is related to the " breathing fun ction". Proper compression is affected by the air cleaner condition. muffler restriction. valve condition and operation including proper valve adjustment. cylinder head gaskets. condition of 51eeves, rings, pistons, camshaft, and camshaft timing. COMBUSTION . CombuS1ion is the reSUlt of adequate comprelsion to develop enough heat in the air charge on the compression stroke to fir. the fuel being injected into the engine cylinders. Proper spray pattern and atomization of the fuel by the Injector is very important. TIming the fuel Injection pump to the engine to a precise degree BTDC is a vital requirement for proper combustion. The engine diagnosis contained in the followIng pagel covers many trouble symptoms. the causes, end what will be necessary to repair or eliminate the problem. Under each symptom are listed the most common and reoccuring problems progessing to the !lot so common problems. Locate your problem symptom in the diagnosis chart and ref.r to the pagel listed for the probable causes and remedi.,.

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ENGINE DIAGNOSIS CHART

REVIEW THE PR08LEM AND DETERMINE THE

EXACT SYMPTOMS.

I ENGINE HARD T O START OR WIU NOT S TART . SEE PAGG' 4 THR U 81

NO SMOKE FROM OHAUST (SEE PAGE 41

SMOKE FROM EXHAUST (SEE PAGES IS " 6}

ENGINE STARTS BUT WIU NOT RUN ISEE PAGES 7 AND 8)

fNGINE "'"SFIRU' (SEE PAGES 9 II.ND 101

ENGINE KNOCKS (SEE PAGES l ' AND 121

ENGINE OVERHEATS ISEE PAGES 13 THRU 151

CNGIN E LACK S POWER ISEE PAGES 16 AND 171

EXTERNAL LEAKAGE (SEE PAG E , 81

HIGH ENGINE OIL CONSUMPTION {SEE PAGES 1 B THItU 201

INTERNAL UAIUlO' .SEE PAG ES

,....j

EXTERNAL PROBLEMS (SEE PAGE 211

INTERNAL PROBLEMS {SEE PAGES 22" 231

19 110 201

I I I

LOW lNGINE OIL PR ESSURE ISEE PAGES 21 THAU 2J)

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2001-4

ENGINE HARD TO START OR WILL NOT START No Smoke From Exhaust 1.Fuel Shut-Off Not Open Completely.

7. Fuel Injection Nozzle Not Seated In Head.

Improper cable adjustment, damaged cable, cable slipping in clamps, misadjusted or inoperative solenoid will not completely return fuel shut路off lever to open position. Check lever to be sure it is opening completely. A partially opened lever limits the amount of fuel to the injection pump and results in lawen路 gine horsepower.

A nozzle that is not seated in the cylinder head will let compression leak by and not produce enough heat to fire the injected fuel. Cheek for damaged nozzle gasket or seals. loose nozzle. or broken stud.

2. Final Air Filter Plugged

8. Fuel Line Plugged A fuel line plugged with dirt will not let fuel through to the injection pump. Remove line at fuel filters and check for fuel flow through line.

A dirty filter will cause rich fuel mixture and low engine power. Check filter restriction indicator and service final air filter if required.

Check and service fuel filters.

3. Slow Cranking Speed

10. Wrong Fuel or Contaminated Fuel

Starter must crank engine 200 to 300 RPM in order to ignite the diesel fuel. Check engine RPM while cranking . If cranking is slow. cheek starter amperage draw to help detennine the following defective areas: batteries, cables. solenoid and starting motor.

Wrong fuel (low centane) or contaminated fuel (water and dirt) can cause the engine not to run or to have pre-combustion, causing serious damage to the engine. Drain fuel tank and refill with correct fuel.

9_ Clogged Fuel Filter

11. Sticking Rack Control Slow cranking speed can be caused by the fol 路 lowing internal and external engine defects; scuffing and scoring of pistons and sleeves, improper crankshaft or camshaft end play. defective rod or crank bearings. oil pump. water pumP. hydraulic pump or air compressor. 4. Fuel Supply Shut-Off or No Fuel Check that fuel tank shut-off valve is open. Check fuel supply in tank. 5. Air In Fuel System Bleed fuel system until fuel flowa steadily with no bubbles. Check for air leaks at fittings between tank and fuel pump. 6. Camshaft Damaged A sheared key in the cam drive gear or a broken cam shaft will throw valve timing out of sequence affecting engine operation. Remove cylinder head cover and check velve timing in reference to crankshaft timing marks with a dial indicator.

A sticking rack control will not let the fuel injection pump accept any fuel. 12. Piston Rings Worn As piston rings become worn. they lose ten路 sion and ability to seal and wipe lubrication oil off cylinder walls. Take a compression test to determine piston ring condition. If readings are low, squirt a small amount of oil into the cylinder and retest. If compression comes up because the oil helps the rings seal, it will be necessary to install new piston rings and possibly sleeve and pistons. 13. lnjection Pump Malfunction A malfunctioning injection pump will usually under-fuel the engine. Adjust or replace the injection pump. A common cause is a sheared key on the injection pump drive. preventing fuel to be dellvered to injectors. Adjust or replace the injection pump.

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2001-5

ENGINE HARD TO START OR WILL NOT START Smoke From Exhaust 1. Slow Cranking Speed

7. Pieton Rings Worn

Starter must crank engina 200 to 300 RPM in ardor to ignite the di>l!M1 fuel . Check engine RPM while cranking. If cranking is slow, check starter amperage draw to help determine the following problem areas: batteries. cables. solenoid, and starting mota •.

As piston rings become worn, they lose tension and ability to seaf and wipe lubricating oil off cylinder walls. Take a comprassion tast to da· termine piston ring condition. If rltl!ldings are low, squirt a small amount of oil into the cylinder and retest. If compression comes up because the oil helps the rings seal, it will be necessary to install new piston rings and possibly sleeve and pistone.

Slow cranking speed can be caused by the fol lowing internal and external engine defects: scuffing and scoring of pistons and sleeves, improper crankshaft or camshaft and play defective rod or crank bearings. oil pump, water pump, hydraulic pump or air compreuor. 2. Fuel Shut-Off Not Open Completely_ Improper cable adjustment. damaged cable, cable slipping in clamps. mi$3djusled or inop· erative solenoi d will not completely return fuel shut-off lever to open position. Check lever to be sure it is opening completely. A partially ofWtned lever limits the amount of fuel to the injection pump and results in low engine horsepower. 3 . low Compression Low compressi on on several cylinders, makes the engine hard to start and rough running, also does not generllte o:Inouoh heat to properly fire on all cylinders. Make a comprassion test on the engine.

B. Velve Pueh Rod. Bent Bent push rods will affect valve operatio n and not allow cylinders to get. full charge of fuel and air, or not exhaust properly. This can u· sually be distinquished by axcessive valve tappet noise. Remove cylinder cover and check for bent push rods. 9. Clogged Fuel Filter Check and service fuel filters.

10_ Fuel Injection Nozzle Not Seated In Heed A nozzle that is not seated in the cylinder head will let compression leak by and not pro duce enough heat to fire the injected fuel. Check tor damaged noule gasket or seals. loose noule, or broken stud. 11. Tune-up Specifications Wrong

4 . Final Air Filter Plugged A dirty filter will c ause ri c h fuel mixtures and low engine power . Check filter restriction indicator and service final air filter if required .

Check engine and unit serial number plate s tor correct speCifIcations whe n perfo rming !:t ogine tune-up. , 2. Piston end Sleeves Scuffed and Scored

5. Fuel Injection Nozzlee Melfunctioning low cracking pressure , improper spray pattern, or pluggad spray orifice will "Heet proper combustion in engine cylinders. Remove and test the h,el injection nozzles. 6. Engine Timing Incorrect Combustion will n01 oCcur in the cylinder at the correct moment (degrees STDer if th" en gine timing is incorrect. This can cause precombustion and serio us damage to the engine. Check for proper engine timinq.

Scuffing starts as a very small surface disturbance of torn out metal particle. This helps break down lublication which increases heat and spreads the scuffing to adjacent areas. Scuffing and acoring are caused by malfunctioning of the lubrication system or cooling aystem, Incorrect timing. pre - combu stion, tuggi ng Or overloading, improperly fitting parts and improper break-in procedure. Remove piston assemblies and inspect.

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2001-6

ENGINE HARD TO START OR WILL NOT START Smoke From Exhaust (Cont'd) 13.Cylinder H . .d G â&#x20AC;˘â&#x20AC;˘ket Blown

1S.Wrong Fuel or Contaminated Fuel

A blown cylinder head gasket will cause one or two cylinders to loose power and cause an engine to miss. Compression leaking into the water system can also cause the cooling system pressure to rise and blow engine coolant out the radiator overflow. Take a compression test to help determine a defective head gasket, or remove radiator cap, run engine and check for gas bubbles rising In coolant at radiator opening.

14. Piston Ring Installation faulty or Broken Rings At times, piston rings are installed wrong. upside down, wrong size, overlapping of eJ(panders, or eJ(p~tnders are cut on three piece oil rings. Be sure to carefully read the instructions before installing piston rings. Damaged rings can cause scoring of the piaton sleeves and cause the engine to use oil. 15. Valves Sticking

17.lnjection Pump Malfunction A malfunctioning Injection pump will usually under-fuel the engine. A common cause is a sheared key on the injection pump drive, preventing fuel to be delivered to injectors. Adjust or replace the injection pump or parts as required. 18. fuel Injection Line Cracked . A cracked, chaffed or damaged fuel injector line will allow the fuel to escape eJ(ternally and not inject fuel into the cylinder. This will cause an engine miss and low horsepower. Leaking fuel from a damaged Injector line can easi1y be seen.

Sticking valves can be caused by improper replacement of valve guides, no lubrication, rust vapors, bent valves. or carbon. A sticking valve will cause an engine miss and the valve could also hit the piston causing internal damage.

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2001·7

ENGINE STARTS BUT WILL NOT RUN ,. fuel Shut·Off Not Open Completaly

8. Camshaft Damaged

Improper cable adjustment, damaged cable, cable .lipping in clamps, misadjusted or inoperative lelonoid will n01 compkltely return fuel .hut·off lever to open position , Check lever to be sure it i. opening completely. A partially opened Illver limits the amount of fuel to the injecdon pump and results in low engine hor· sepower.

A sheared key In the cam drive gear or a bro· ken CIImshaft will throw valve timing out of sequence, affecting engine operation . Remove cyfinder cover and check valve timing in ntference to crankshaft timing martls with i dial indiCillor.

2. final Ai, filter Plugged

9. WronR Fual or Contaminated Fuel

A dirty filter will eause rieh fuel milrtures and low engine power. Check filter restriction indicator and service final air filter if required.

Wrong fuel (low centene, or contaminated fuel I'lllater and dirt) can cause the engine not to run or 10 hive pre·combustion, causing serious damage to the engine. Drain fu.1 Ulnk and refill w ith correct fuel.

3.Alr In fuel SYltem

10.Clogged fual Filter

Bleod fu.1 'yS1em until fuel flowl steady with no lIir bubbles. Check for air leaks at tittingl bMWeen fuel tank and injection pump.

Check and service fuel filters.

4. Low Fuel Supply

11.Fuel Injection Noala. Malfunctioning

Cheek fU1I1 supply in tank Ind relil if nee85sary.

low cracking pressure, improptl!r spray pettern, Of plugged spray orifice will affect proper combustion in engine cylinders. Remove and test the tuel injection noules.

6.ln;ectlon Pump Rllck Control Sticking

12. Cylindar Head G.lket Blown

A Iticking rack control will not allow the fuel injection pump to accept any fuel.

low compression on several cylinder•• makes the engine hard to s tart and rough running, al.o dOtls not gena.at. onough he.t to pro_ perty fi.e on all cylinders. Make a compression test on the engine.

A blown cylinder haad gasket will cause one or two cylinders to loose power and cause an engine to miss. Compression leaking Into the water system can also cause the cooling IY$' tern pressur. to rise and blow engine coolant out the radiator overflow. Take a compliltQion test 10 help determine a defective head gasket, or remove radiator cap, run eng ina and check for gas bubbles rising in coolant al ,.dialOr opening.

7. Valve Push Rodl Sent

13. Pilton Rings Worn

Bent push rod. will affect valve operation and not allow cylinders to get II fun charge of luel and air, or not e)[haust properly. This can ulually be diltinquished by eXC8uive valve tappet noise . Remove cylinder cover and check for benl push rods.

As piston rings become worn, they lose tension and ability to seal lind wipa lubricating oil off cylinder walls. Take a compression test to determine piston ring condition . If raadings afe low, squirt a small amount of oil into tho cylindef and retelt. If compression comes up becaule the oil heipi the rings seal. It will be necessary to Inltill new piston ring. end pos· sibly sleeve and pistonl.

6.Low Compralsion

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2001-8

ENGINE STARTS BUT WILL NOT RUN (Cont'd) 14. Valves Sticking

l6.Fuel Injector Line Cracked

Sticking valves can be caused by improper replacement of valve guides. no lubrication, rust vapors, bent valves, or carbon . A stick· ing valve will cause an engine miss and the valve could also hit the piston causing internal damage.

A cracked. chaffed or damaged fuel injector line will allow the fuel to escape externally and not inject fuel into the cylinder. This will cause an engine miss and low horsepower. leaking fuel from a damaged injector line can easily be seen.

l6.lnjection Pump Malfunction

17.lnjection Pump Timing Incorrect

A malfunctioning injection pump will usually under-fuel the engine. A common cause is a sheared key on the injection pump drive. pre-venting fuel to be delivered to injecton!. Ad· jUfl or replace the injection pump or parts as required.

A fuel injection pump timed at wrong degrees, wrong stroka. or marks moved on pulley, .....iII inject fuel into the cylinders at the wrong time, causing rough running, pre·combustion, low horsepower and other damage to the engine. Check for proper pump timing .

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2001·9

ENGINE MISFIRES Low and High RPM ,. Wrong Fuel or Contaminated Fuel

7. Fuel Injection Line Cracked

Wrong fuel (low centane) or contaminated fuel (water and dirt) can cause the engine not to run or to have pre·combustion. causing serious damage to the engine. Drain fuel ·tank and fit· fill with correct fuel .

A cracked, cha ffed or damaged fuel injector line will allow fuel to escape externally and inJect fuel into the cylinder. This will cause an engine miu lind 10- ho .... power Leaking fuel from a damaged injector line can easily be sean.

8. Injection Pump MalfunctIon. Bent push rods will affect valve operation and not allow cylinders to get a full charge of fuel and air. or not exhaust property. Thi, co n u · sually be distinquished by excessive vatve tap· pet noise. Remove cylinder cover and check for bent push rods.

A malfunctioning injection pump will usually under' fuel the engine. A common ctluse is a sheared key on the injection pump drive, preventing fuel to be delivered to injectors. AdJust or replace the injection pump or parts liS required.

3. Fuel Injection Noule. Malfunctioning 9. Injection Pump Timing Incorrect Low craclting p'lI'!ssUfe. improplI'!f spray pattern or plugged orifice will offect propor combustion in engine cylinders. Isolate faulty injector noule and remove . A . Fuel Injection Noule Not Seated in Heed A tuel injection nonte that is not seated in the cylinder head wilt let compression teak by and the cylinder does not produce enough heat to fire the injected diasel fuel . A damaged nozzle 08$k,U or seals. loose nozzle. or broken stud can cause the nozzle not to be seated correctly.

A tuel injection pump timed It wrong degree., wfong stroke, or marks moved on pulley, will inj.ct fuel into the cylinders at the wrong time, causing rough running. pre·combustion. low horsepower and other damage to tha engine. Check for proper pt.mp timing . 10.ln1:aka Manifold Gasket Damaged A damaged intake manifold gasket can fe· duce the manifold pressure and ctlusa an insuNlclent air-fuel mixture in tho cylinderc and result in low power.

5. Cylinder Head Gasket Blown 1'.Cylinder Haad or Sleeve Crackad A blown cylinder head gasket will cause one or two cylinders t o loose power and cause an engine to miss. Compression leaking into the water sYltem can also cause the cooling system pressure to rise and blow engine coolant out the radiator overflow. Take a compression test to help determine 8 defective head gasket, or remove rad iator cap, run engine and check for gas bubbles rising in coolant at radiator opening.

A c racked head or sleeve will usually let an-gina coollint into the engine. Th is will cause an engine miss Of pressure riae In the cooling sys' tem depending on how bad the leek is. Low COOlant level, oil level. engine missing, and blowing water out tha exhaust are evidence that coolant is gotting into the eng;ne combustion chambers.

6. Low Compression Low compression on several cylinders, makes the engine hard 10 start and rough running • • Iso does not generate enough heat to properly fire on all cytindatS. Make a compression test on the engine.

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2001·10

ENGINE MISFIRES Low and High RPM (Cont'd) 12. Valves Damaged

16. Valves Sticking

Damaged valves are caused by wear, improper grinding, hitting the pistons, wrong adjustment, loose seat. or broken valve spring. Defective valves can usually be heard through the intake or exhaust manifold. A low reading compression test usually indicates defective valves.

Sticking valves can be caused by improper replacement of valve guides, no lubrication, rust vapors. bent valves or carbon. A sticking val\ffl will cause an engine miss and the valve could also hit the piston causing internal damage. 17. Bent Connecting Rod

13. Valve Spring Worn (High RPM) Weak valve springs will allow the valves to float at high speed. Broken valve springs will not close valve completely and valve could hit the piston doing internal engine damage. Always check and test valve springs when doing a valve job. Damping coils on spring should be as· sembled against the cylinder head. 14. Operating Temperature low The engine was designed for and will only develop full horsepower within its correct op· erating temperature range. Low operating tern· perature can result from a malfunctioning ther· mostat. Do not remove thermostat during the summer. Maintain 50% of permanent anti· freeze all year for more efficient operation.

A bent connecting rod will cause piston slap from scoring due to misalignment. The engine will run rough because of incomplete combus· tion and emit white exhaust smoke from the bad cylinder. Remove engine oil pan and inspect connecting rods for alignment. A com· parison of piston heights at Top Dead Center with cylinder head removed may quickly in· dicate a bent rod condition. A difference of .020 inch in connecting rod can cause a noticeable miss at low R PM and cold engine conditions. 18. Tune-up Specifications Incorrect Check engine and unit serial number plates for correct specifications when performing engine tune-up.

15. Engine Pre-combustion Pre·combustion is the igniting of the fuel be· fore the nonnal compression point occurs. This can cause severe knocking and engine power loss. High temperature and pressure from pre·combustion will cause other serious internal damage to the engine. The following are causes of pre-combustion: A. Valves operating at higher than normal .temperature because of e;JCcessive guide clearance or improper seal with valve seats. B. Hot spots caused by an inefficient or dam· aged cooling system. C.lnjection noules set at incorrect cracking pressure. D. Sharp edges in combustion chamber. E. Timing incorrect. F.E;JCcessive lugging of engine. G. Defective injection pump. H. Wrong or contaminated fuel.

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, 2001-11

ENGINE KNOCKS Low and High RPM 1. Engine TIming Incorrect

5 . Main Baaring Worn

Combustion witt not occur in the cylinder at the correct momsnt (degrees BTDe) If the en-

A worn main bearing will have 8 thudding sound and increased engine vibration. Both symptoms will increase as engine speed increases. By grounding out {cracking injector line} the problem cylinder. the thudding sound will stop or decrease but the vibration will remain . RemO\l$ engine oil pan and check main bearing clearance will plasti -gauge. Also. l ow oil pre.sure can be the result of worn main bearings and excessive oil clearance.

gine timing is incorrect. This can cause precombustion and serious damage to the angine.

Check for ptoper engine timing. 2 . Flywheel

loosa

{ Low RPM}

A loose flywheel witt chuck or pound at low speed making the engina sound like it has a

loose connecting rod. As speed increases, the knock will go away. Replica flywheel if badly

worn.

6. Piston and Sleeves Scuffed and Scored

3. Engine Pre-combullltion

Scuffing starts as a very small .urface disturbance of torn out metal particles. This help. break down lubrication which increases heat and spread, the scuffing to adjacent .r.... Scuffing and scoring are caused by malfunctioning of the lubrication system or cooling system. incorrect timing, pre-combustion. lugging or overloading. improperly fitting parts and improper break-in procedure. Remove piston assemblies and inspect.

Pt.-combustion is the igniting of the fuel before

the nOnTlal compression

point occurs.

This can cause severe knocking and engine power loss. High temperature and pressure from pre- combustion will cause other serious

internal damage to the engine. The following are causes of pre-combustion; A _Valves operating at higher than normal temperature becausa of excessive guide ciearan ce or improper seal with valve seats. B . Hot spots caused by an inefficient or dalnaged cooling system. C.lnjection nozzles set at incorrect cracking pressure. D . Sharp edges in combustion chamber. E. Timing incorrect . F. Excessi ve lugging of angine. G. Defective injection pump. H. Wrong or contaminat ed fuel.

7. Piston Ring Installation FaUlty or Broken Rings At times. piston rings are installed wrong, upslda down. wrong si:i:e. overlapping of ex pandars, or ellC~nders are cut on three piece oil rings . Be sure to c arefully rllad the in.tructions before in.talling piston rings. DamÂˇ aged rings can cause scoring of the piston sleeve. and cause the engine to use oil.

4_ Rod Bearing Worn A rod bearing going bad will have 'lI sharp metallic sound which will increase as RPM increa.es. When the cylinder with the bad knock is grounded by cracking the Injector line, the knock will stop or decrease considerably. Remove the engine oil pan and check rods with plasti. gauge.

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2001-12

ENGINE KNOCKS Low and High RPM (Cont'd) 8_ aent Connecting Rod A bent connecting rod will cause piston slap from scoring due to misalignment. The engine will run "rough because of incomplete combustion and emit white exhaust smoke from the bad cylinder. Remove engine oil pan and inspect c onnecting rods for alignment. A comparison of piston heights at Top Deed Center with cylinder heads removed may quickly indicate a bent rod condition. A difference of . 020 inch in connecting rod can caule a noticeable milS at low RPM and co kl engine con· ditions.

and forth . Check crankshaft end play w ith a dia l indicator. 13. Foreign Material In Cylinders Foreign material such as pieces of broken valve, b o lts, nuts, washers, or pieces of c astings. in the c ylillder will cause a noise everytime the piston comes to Top Dead Cente r. The no ise will not change by shorting out the cylinder. Due to the metal· to-metal contact. the vi bratlon can be felt on the side of the engine . Remove cylinder heads and inspect. 14_ Cylinder Ridge Not Removed

9. Valve Spring Weak Weak valve springs will allow the valves to float at high speed. Broken valve springs will not close valve completely and valve could hit the piston doing internal engine damage. Always check and test valve springs when doing a valve job. Damping coils o n spring should be assembled against the cylinder head. 10. Piaton Pin or Bushing Worn Piston pin or bushing knock will Increale with speed . When grounding out the cylinder (cracking Injector line) the knock will be twice as bad. Due to combustion, every other revolution will keep the piston pin and bushing tight giving no knock. Remove and inspect piston asse mbly pro· ducing the knock. " . Camshaft Bearing Worn A camshaft bearing knock is not a very s harp sounding knock. The knock will be only at onehalf of crankshaft speed and will not become worse at different engine speeds . low oil presaure could result from worn bearings and excessive oil clearance from lack of replacing cam bearing at engine overhaul. 12. Crankshaft End Play Excesaive Exces sive crankshaft end play will be indicated by one thudding soulld when increasing RPM and o ne thud when decreasing RPM . Pilii' to the angle of the teeth on crank gear and cam gear. as speed changes it pushes the crankshaft back

When performing an engine overhaul and installing new rings, the cylinder ridge must be removed. If the ridge was not removed , it would cause the engine to knock on all cylinders as the top piston ring hits the ridge on every s troke. If the top ring continued to hit the ridge, It would cause ring land breakage between top anc! second ring. caus ing piston and sleeve scuffing and scoring . Remove heads and check for cylinder ridge. 15. Improper U.e of Ether (Low RPM) Spraying either into the engine air intake without cranking the engine. will cause one or more cylinders to re ceive a large amount of ether due to open valves. Then, when the engine is cranked, volatile. uncontrolled explosions will occur in these cylinders breaking ring lands alld damaging the piston. Be sure engine is cranking before usillg ether. Re move cylinder heads and inspect pistons for damage. , 6. Camshaft End Play Exce••ive Excessive camshaft end play will be Indic a ted by one thudding sound when Increasing engine speed and one thud whe n decreasing speed. but will not be as pronounced as crankshaft end play. Due to the angle of the teeth on crank gear and cam gear. as engine speed changes. It pushes and pulls the camshaft beck and forth . Elilcessive camshaft end play can be caused by wom thrust washer. loose cam gear, er broken or missing camshaft thrust spring. Remove front timillg cover and check camshaft end play with a dial indicator.

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2001·13

ENGINE OVERHEATS 1. Fan Belt Loose Check

fan

belt

for

proper

tension.

Check

that the belt is not covered with oil or worn badly and liding very deep in pulley groove. Check for pulley groove wear. 2. Low Coolant Level Check coolont if necessar)'.

le ve l

I'8dletor and

refill

the

radiator cap and

observe

the

coolent to see if there is movement which indice tes the woto. pump i. pumping. Move the fan back and forth to check tor any def-

ective

bearings.

Check

9. Radiator Fins Plugged With Dirt Radiator fins mu,;t be clean so air can flow through the radiator fins and help dissipate the heat of the coolant. Items that affact radiator cooling are: all and grease on fins , leaV1ts, "and- attachments covering ra diator air Inlet. 10.Cylindar Head Gasket Blown

3. Water Pump Malfunction Remove

flow through the radiator core. All of the fin area is needed to dissipate tha engine heat from the radiator.

around

the

water

pump for any signs of coolant leakage Indicating a bad water pump 58al. Remove water pump and rebuild or replace. 4. Thermo.ta t Inoperative If there is high coolant temperature and boiling coolant, remove thermostat and test it.

5. Engine Timing IncorTeet Combustion will not occur in the cy~nder at th& correct moment (degrees BTDC) if the engine timing is incorrect. This can cause pre-combustion and serious damage to the engine. Check for proper engine timing.

A blown cylinder head gaskat will cause one or two cylinders to loose power and cause an engine to miss. Compression leaking into the water system can also cause the cooling sys· tem pressure to rise and blow engine coolent out tha radiator overflow . Take a compression test to help de lennine a defective head gasket, or remove radiator cap, run engine and check for ges bubbles rising in coolant at radiator opening. 11. Injection Pump Malfunction A malfunctioning injectlon pump wU/ usually under·fuel the engina . A commo n cause is a sheared key on the injection pump drive, prevonting fuel to be del ive red to injec tors. Ad· just or replace the injection pump or parts as required. 12. Radiator Baffling MiSliing

6 . Tractor Mechanical Drag

A mechanical drag on a unit can cause low horsepower and engine overheating. Causes of some mechanical drags are defective 'brakes, bad bearings o r gears in transmission.

The removal of or non·reinstalling of radia tor baffling, whether foam rubber or sh&et metal, will cause cooling air flow to escape around the radiator instead of drawing in cool tI"temal (lir through the radiator.

7 . Radiator Cap Inoperative

13. Engine Low On 011

...

Test radiator cap to see that it relieves at the correct pressure. Inspect cap gasket for proper sealing. An inoperative cap can cause water pump cavitation and lower coolant boiling points.

8. Radiator Fina Bent

• Bent . or damaged fins can cause 8 cooling system to overheat because of restricted air

-. •

An engine Iowan oil could lose lubrication to internal ,parts and start scoring pistons, lileeves and damage angine bearings. Proper oil laval is required to help dissipate some of the engine heat. Check engine aU level every eight hours of operation. Low engine oil can also give Jaw oil pressure raadings.

•

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ENGINE OVERHEATS (Cont'd)

Wrong fu el (low centane ) or contaminated fuel

A 70% mixture will raise the boiling point to 253 degrees. With just water in the above cooling system, it would boil at 233 degrees.

(water and dirt) can cause the engine not to run or to have pre-combustion, causing serious

20. Cylinder Stuve O.Ring Oamaged '

14.Wrong Fuel or Contaminated Fue'

damage to the engine. Drain fuel tank and refill with correct fuel .

15.Piaton and Sleeves Scuffed and Scored

Scuffing stan, as a very small surface disturbance of tom out metal particles. This helps break down lubrication which increases heat and spreads the scuffing to adjacent areas. Scuffing and scoring are caused by malfunc-

tioning of the lubrication system or cooling system, incorrect timing, pre-combustion., lugging or overloading, improperly fitted parts and improper break-in procedure. Remove piston

A pinched. rolled, nicked, or hard sleeve O-ring can cause a coolant leak in the crankcase, contaminating the engine oil. This cool· ant leaking can go undetected for sometime causing engine heating and ·crankshaft damage. Remove engine oil pan and obSOlVe bottom of sleeves to detect slow coolant leak. 21.Radiator Leaking Externally Inspect and repair or replace leaking radia· tor.

assemblies and inspect.

22. Tune·up Specifications Wrong

16. Water Pump Hose Worn

Check engine and unit serial number plates for correct specifications when performing engine tune·up.

Water pump hoses can become worn from age and collapsing, cracking, chaHing against something or fan belts cutting through them. Inspect hoses for coolant leaks. 17.Bad Ground .on Gauge or Sending Unit A bad ground on gauges or sending units can many times be the only problem with, a defective gauge. Take a jump wire and ground 9auge or sending unit to machine, then recheck gauge. Pipe tape Is often used to seal threads on oil sending units which destroys the biggest share of its' grounding a bility. 18.Cylinder Head or Sleeve Cracked . A cracked cylinder head or sleeve will usuaUy allow engine coolant into the engine. causing engine miss or pressure rise in the cooling system depending upon how bad the leak Is. Coolant leval low. oil levEoI check. engine missing when first started. and water blowing out the exhaust are indications that coolant is getting into the engine combustion chambers.

"-. 19. Lack of Anti-Freeze To illustrate the importance of having antifreeze in the cooling system year around. consider the following. Any ethylene glycol antifreeze with a 50% mixture and a 7 PSI cap will raise the coolant boiling point to 242 degrees.

23. Engine Pre-combustion Pre·combustion is the igniting of the fuel be· fore the normal compression point occurs. This can cause severe knocking and engine power loss. High temperature and preSlure from pre-combustion wilt cause other serious internal damage to the engine. The following are causes of pre·combustion: A. Valves operating at higher than normal temperature because of el(cessive guide clearance or improper seal with valve seats.' B. Hot spots caused by an inefficient or dam· aged cooling system. C.lnjection nozzle. set at incorrect cracking pressure. D.Sharp edges in combustion chamber. E. Timing incorrect. F. Excessive lugging of engine. G. Defective injection pump. H. Wrong or contaminat~d fuel.

24. Water Temperature Gauge Malfunction The water temperture gauge, wiring, resist. tor or sending bult could give false or no temperature readings. To diagnose, remove wire at sending unit and ground to tractor. Turn key switch on. If gauge comes up, sending unit is malfunctioning. If gauge does not come up, use voltmeter and ohmeter to check wiring circuit.

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2001·15

ENGINE LACKS POWER 1. Fuel Shut-Off Not Open Comp letely

8. Low Compre•• ion

Improper cable adjustment, damaged cable, cable slipping in clamps, misadjusted or inoperative solenoid will not completely return fuel shutoff lever to open position. Check lever to be sure it is opening completely. A partially opened lever limits the amount of fuel to the injection pump and results in low engine horsepower.

Low compression on several cylinders makes the engine hard to start and also does not gen· erate enough heat to properly fire on all cylin· ders and continue running. Make a compreSiion check on the engine.

2. Low Engine RPM Check engine tor correct RPM.

9. Fuel Injection Nonles Malfunctioning Low cracking pre $Sure. improper spray pat· tern. or plugged spray orifice will affect pro· per combustion in engine cylinders. Remove and test the fuel injection nozzles.

3. TUlctor Mechanical Drag 10.Clogged Fuel Filter A mechanical drag on a unit can cause low horsepower and engine overheating. Causes of some mechanical drags are damaged brakes. bad bearings or gears in transmission. 4. Final Air Filter Plugged A dirty filter will cause rich fuel mixtures and low engine power. Check filter restriction indicator and service final air filter if required. 5. Wrong Fuel or Contaminated Fuel

Check and service fuel filters. 11.Air In Fuel System Bleed fuel system until fuel flows steady with no air bubbles. Check for air leaks at fittings between fuel tank and injection pump.

12.Camlhaft Timing Wrong

Wrong fuel or contaminated fuel can cause the engine not to run or to have pre-combustion. causing serious damage to the engine. Drain fuel tank and refill with correct fuel.

A camshaft can be installed one tooth out of time making ali valves operate out of normal timing sequence in relation to the crankshaft. This wouid not a llow the engine to develop full power or run smoothly. Valves could hit the pistons causing internal damage .

6. Operating Temperature Low

13. Crankca•• Too Full of Oil

The engine was designed for and will only 'develop full horsepower within a specific tern· perature range. Low temperature can result from defective thermostat. 00 not remo~ ther· mostat during summer. Maintain 50% of permanent anti·freeze all yeer for more efficient operation.

An over·full or completely full crankcase can cause a loss of power because the crankshaft is trying to tum in the extra high oil level. High oil level can be caused by coolant or fuel leakage into the crankcase. extra engine oil. or oil transferred from an adjoining com· partmant.

7. Engine Timing Incorrect Combustion will not occur in the cylinder at the correct moment (degrees BTDCl if the engine timing is incorrect. This can cause pre-combustion and serious damage to the engine. Check for proper engine timing.

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2001-16

ENGINE LACKS POWER (Cant'd) 14_ Valves Damaged

17_Fuel line Plugged

Damaged valves are caused by wear. improper grinding. hitting the pistons. wrong adjustmant. loose seat. or broken valve spring. Defective valves can usually be heard through the intake or exhaust manifo ld. A low reading compression test usually indicates defective valves.

A fuel line plugged with rust or dirt wilJ not allow fuel through to the fuel injection pump. Remove flne at injection pump and check fuel flow.

18. Engine Drag Lack of power can be caused by the following internal and external engine defects:scuffing and scoring of pistons and sle eves. improper crankshaft or camshaft end play. wom rod o r crenk bearings. oil pump. a ir compressor. water pump. or hydraulic pump.

15. Velvee Out of Adjustment Careful valve adjustment is important to obtain a complete supply of fuel and air and to completely exhaust burned gases. Valves out of adjustment can cause damaged valves, valve seat wear. bent push rods. damaged . pistons. rocker arm wear and camshaft wear. 16_lnjection Pump Malfunction

·,.

A ma!functioning injection pump will usually under-fuel the engine. A common cause is a sheared key on the injection pump drive. preventing fuel to be delivered to injectors. Adjust or replace the injection pump or parts as required. • •

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2001-17

HIGH ENGINE OIL CONSUMPTION External leakage 1. Engine External Oil Leakage Check for engine external oil leaks at the following locations: A.Covers B. Accessories C. Valve cover gasket O.Restricted breather E. Oil pan gasket F. Timing gear cover gasket G.Extemal oil lines H.Camshaft welch plug I. Engine oil filter J . Engine oil cooler K. Oil drain plug gasket L. Front and rear crankshaft seal

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2001-18

HIGH ENGINE OIL CONSUMPTION NOTE; CHECK CRANKCASE BREATHER FOR BLOW-BY AND EXHAUST FOR BLUE GRAY SMOKE.

1. Engine Internal Oil leakage

S. Pleton Rings Worn

Cheek for engine internal oil leaks in the cylinder head assembly and engine block aSlem· bly.

As p iston rings become worn, they lose tension and ability to seal and wipe lubricating o il off cylinder walls. Take a compression test to de· termine piston ring condition. If readings are low, squirt a small amount of oil into the cyl· i nder and retest. If compression comes up because the oil nelps the rings seal. it will be necessary to install new piston 'ings and pos· slbly sleeve and pistons.

2. Valve Guides Worn Excessively worn valve guides can account for high oil consumption. Gravity. inertia and air pressure differences act to fon:e oil through the intake and exhaust valve guides. To check· out valve guides, restrict lubricating oil flow to the rocket assemblies for a short time. Run engine at idle and then accelerate quick· Iy. If dark blue exhaust clears up. the valve guides are worn and defective. 3. Rocker Arm Assembly Worn Worn rOcker arm assemblies allow larger than normal amounts of lubricating oil into the valve compartment. The extra quantity of oil increases oil c onsumption past the valve guides. Run the engine with valve cover removed and check for excessive oil or oil flow from the rocker arms. 4 . Ph.ton and Sleeves Scuffed and Scored Scuffing starts as a very small surface dis· turbance of 10m out metal particle. This helps breakdown lubrication which increases heat and spreads the scuffing to adjacent areas. Scuffing and $Coring are cau$ed by malfunctioning of the lubricating system, or cooling system, incorrect timing, pre·combustion, lugging or overloading, Improperly fitted parts and improper break·in procedure. Remove the piston assemblies and inspect.

6. Rocker Arm Shafts Indexed Wrong Incorrect rocker arms or rocker arm shafts indexed wrong can lead to excessive oil in the rocker arm compartment. This oil aggravates oil consumption especially past valve guides. Remove valve cover and check oil flow from rocker arm assemblies. 7. Excessive Oil In Rocker Arm Compartment Excessive oil in rocker arm compartments can be caused by wrong tacker arms, rocker arm shafts indexed wrong. worn rocker arm bush· ings, high oil pressure and poor oil drainage back to crankcase. Remove cylinder cover and check for above problems. 8. Engine Speed Too High Running at speeds higher than ths engine is designed for will aggravate all oil consumption areas such as oil pressure, oil flow. throwoff onto cylinder walls and oil in rocker arm compartments. Check engine speeds and set according to specifications. 9 . Connecting Rod aearinga Worn Worn rod bearings cause more than normal throw·off of lubricating oil to cylinder pistons and liners. This excess oil is sometimes more than worn piston oil rings can control. The oil then passes ths rings and on into the combus· tion chamber. Remove the engine oil pan and check rod bearings for wear using plasti-gauge. A worn rod bearing can cause the engine to knock and low all pressure.

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2001-19

HIGH ENGINE OIL CONSUMPTION

10. Engine Oil Too Light Using engine oil that is too light will aggralIate an oil conGumption ar... bIH:llute of additional oil flow and leakage of the lighter oil. light engine oil will give lowor than normal oil pressure readings. Check for proper weight oil and change oil if required. " . Piston Rings Not Seated Malt piston rings will Hit In the first few hours of operation. If engine continual to use a ll. it is usually a problem other than piston rings. Items that can caule rings not to seat a.a: out-at-round sleeve. warped sleeve. improper deglazing of sleeves. rings installed wrong or improper break· in procedure. Do not add abrasivElS to intake Iystem to seat rings. If it is suspected thet rings are not seated. toar down engino and inspect. 12. Valve Guide Seals Wom Wom lIall1e guide seall allOW oil to enter tho engine through the lIalve guides. Gravity. inertia and air pressure differences all act to force oil through the intake and el(haust valve guides and into the combustion chamber. Remove rocker ann assembliel and valve .prings and inspect or replace valve guide .eal• . 13 . Engine Oil Pressure Too High

, 4. Piston Ring Installation Faulty or Brokan Ring. At times. piston rings are tnstallad wrong. upsida down. wrong size. overlapping el(' panders. or el(pandars are cut ott on three piece oil rings _ Be sure to cartlfully read instruc1ions before intrlalling piston ring._ Dam· aged rings can cause scoring of lhll pis Ion sleevel and cause the engine to use oil. 15.Cylinder Head Gaskat Damaged A cytindaT held gasket can be damaged or instetled wrong allowing lubricating 011 to en· ter the combu.tion chamber and to be burnacl in tha engine. Remove cylinder head snd check gasket If all other tests check o ut all righl. 16 . Oil Leakage Past Valva Guidel and Valva _ El(cvs,/vI:I ... olve stem-to·guide cloO fance can causa high oil consumption . A haavy carbon build· up on valve stems and face is the reo suit of el(cessive oil leakage past vilille guides. also a noticeable loss 01 engine power could result _ In many cases. teflon valva seals will restore engine oil economy withou t the neces· sity of a complete engine overhaul. This is panicularly true where the angine has low hours and the piston rings are in good condition. yet there has been a record of poor oil economy from tha Itan. Refer to Page 24 for Intrlillation of Teflon Valve Seals.

High oil pressure will cau" add itional oil throw-off from connecting rod bearings for lubrication of cylinder walls. This additional oil mey ba more oil than worn piston rings can control. High oil pressure will ceusa excessive oil in all areas and can cause all consumption . Remove engine oil pan and adJu.t all pump ra· lief valvo .

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2001·20

LOW ENGINE OIL PRESSURE External Problems 1. External Oil Leakage

4.0il Pre •• ur. Gauge Wiring Damaged

Check for oil leakage at the oil filter, ex· ternal oil lines and oil cooler.

PreSiure gauges can malfunc tion and provide false readings. Tests with more than one gauge to be certain the re adings are correct.

If the gauge wiring is grounded at the iending unit with the key on and no gauge reading, the problem lies in the gauge or wiring. Hook a jumper wire from gauge terminal to ground and tum on the key. If a reading is obtained. the problem lines in the wiring. Re plac e the wiring harness or run a sepa· rate wire for o il pressure gauge.

3 . 011 Pres.ure Sending Unit Malfunction

5. Bad Ground On Gauge or Sending Unit.

Disconnect wire from sending unit to dash gauge. Ground this wire and turn on key switch , If gauge comes up, problem is in the sending unit.

A bad ground on gauges or sending units can many times be the only problem With a malfunctioning gauge. Take a jump wire and ground gauge or sending unit to machine, then recheck gauge. Pipe tape is often used to seal threads on oil sending units which destroys the biggest share of its' grounding ability.

2. Oil Pr••• ure Gauge Malfunction

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2001-21

LOW ENGINE OIL PRESSURE

Internal Problems 1. Engine Low On Oil An engine low on oil could Jose lubrication to internal parts and start Icoring pistons. sleeves and damage engine bearings. Proper oil level is required to help dissipate some of the engine heat. Check engine oil level every eight hours of operation. Low engine oil can also give low oil pressure readings. 2. Oil Pump Relief Malfunction Low engine oil pressure readings can be caused bv a malfunctioning oil pump relief valve. A broken spring, a piece of metal under velve seat or abrasives could cause relief valve to score and hang up. Remove engine oil pan and oil pump assembly. Inspect pump relief valve and repair as necessary.

By grounding out (cracking injector line) the problem cylinder, the thudding Jound will stop or decrease but the vibration will remain. Remo\/e angine oil pan and check main bearing clearance with plasti-gauge. Also, low oil pressure can be the result of worn main bearings and e)llcessive oil clearance. 7. Connecting Rod Bearings Worn Worn rod bearings cause more than normal throw oH of lubricating oil to cylinder pistons and liners. This excess oil is sometimes more than worn piston oil rings can control. The oil then passes the rings and on into the combustion chamber. Remove the engine oil pan end check rod bearings for wear using plastiÂˇ gauge. A worn rod bearing can cause the engine to knock and low oil pressure. 8. Rocker Arm Shafts Indexed Wrong

3. Engine Oil Too Light Using engine oil that is too light will aggravate all oil consumption areas because of additional oil flow and leakage of the lighter oil. Light engine oil will give lower than normal all pressure readings. Check for proper weight oil and change oil if required.

Incorrect rocker arms or rocker arm shafts indexed wrong can lead to excessive oil in the rocker arm compartment. This oil aggravates oil consumption especially past valve guides. Remove valve cover and check oil flow from rocker arm assemblies. 9. Rocker Arm Assembly Worn

4. Oil Pump Suction Assembly Off Pump

It Is possible for the oil pump suction assembly to come off the engine oil pump from improper installation. defective threads or jam nuts or worn cotter pin holding on the suction screen. With the pick up screen off. the pump would have little or no oil pressure. Remove oil pan and inspect oil pump suction assembly. 6. Engine Oil Pump Worn The engine oil pump can be worn from long service, contaminates in the oil, improper installation or no backlash in pump drive gear. Remove engine oil pan and inspect oil pump. 6. Engine Main Bearings Worn

Worn rocker arm assemblies allow larger than normal amounts of lubricating oil into the valve compartment_ The extra quanitity of oil increases oil consumption past the valve guides. Run the engine with \/alve co\/er removed and check for excessive oil or oil flow from the rocker arms. , O. Oil Pump Suction Screen Plugged The 011 pump suction screen can become plugged with sludge, metal filings and other contaminants in the oil. Many times the oil pressure will be normal when engine is first started . The longer the unit runl, the more contaminants are collected on the pick-up screen shutting off the supply of luction oil. Remove engine oil pan and inspect oil pump screen.

A worn main bearing will have a thudding sound and increased engine vibration. Both symptoms will increase as engine speed increases.

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2001路22

LOW ENGINE OIL PRESSURE Internal Problems (Cont'd) 11.lnternal Oil Passage Leek

13. Camahaft aaaring Worn

A erack. mining plug. or bad "0" ring could cause an internal oil gallery leak resulting in low oil prelsura readings. Another pouible leak is the "0" ring that Hals bet路 ween the engine oit pump and oil gallery. If luch leakage is suspected. attach air pressure to tha oil gallery and watch fo r leaks with oil pan removed.

A camshaft bearing knock is not a very sharp sounding knock. The knock will be only at one路 half 01 crankshaft speed and will not become worse at differem engine speeds. Low oil pressure could result from worn bearings and ex路 cessive oil clearance from tack of replacing cam bearing lit engine overhaul.

12. Key In Oil Pump Gear Worn The key in tha oil pump drive gear could become worn and sha.r. Remove oll pan snd oil pump. disah8mble oil pump and inspect.

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2001·23

INSTALLATION INSTRUCTIONS FOR M20611 TEFLON VALVE SEAL KIT Special Tools Required

".20616 VALVE GUIDE CUTTING TOOL M20624 SEAL INSTALLATION TOOL

Remove the cylinder head from the engine block. Refer to section 2015 for he.d removal. NOTE: This cylinder head requires two

VALVE SPRING COMPRESSOR

Install a valve spring compressor.

M20611 Kits.

Place cylinder head on work bench.

Compress valve spring and remove valve keepens. IMPORTANT: V.lve$ and volve kee per. should be marked when removed to in· sure that they will be reinstated in their original location .

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2001-24

Remove spring retainer.

Remove valve stem seat.

Remove spring.

Remove valva.

Remove spring seat.

Remove atl the valve assemblies.

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STEP 13 D

MINIMUM 1/16

Wash, clean and inspect head. Use a rotary brush to clean around and down into valve ports. Refer to Section 2015 for complete head reconditioning.

WIDE fLAT

\.::::::

STEP 12

Clean valves with a fino power drive wire brush, removing all carbon and varnish daposits. Be careful not to scratch valve stems. Reter to Section 2015 for valve inspection.

Check valve guide top surface. There must be a minimum of a 1 / 16" wide flat around entire top surface.

Use M20615 tool in a electric drill (if required) to provide necessary flat area on valve guide. IMPORTANT: Do not exceed 450 RPM drill speed when using valve guide cutting tool.

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Dip valve stems into HOM #30 oil before aaaembly in cylinder head.

Carefully start valve seal on cap and hold thumb against white seal insert to avoid disÂˇ lodging it. Push seal down until seat jacket touches top of valve guide.

Install spring seat. Remove installation cap and 18ve. since it must be reused.

Place plastic installation cap. provided in kit. on the end of the valve stem. NOTE: Cap prevents sharp edges on valve litem grooves from cutting valve seal.

Use M20624 tool and press seal down over valve guide until seal is flush with top of guide.

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2001Âˇ27

Valve seal Installed.

Install valve spring compressor.

STEP 22

CLOSED OAMPING COIL ENO

Install stem seal in lower velve stem groove.

Install spring (damping coil end down) and spring ratainer.

Install

valve

keeper. in

outer

valve

.tern

groove.

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2001-28

Remove spring compressor and stem end to seat keepers.

tap

valve

Install cylinder head on engine block following procedure outlined in Section 2015.

Install teflon seals on the other intake and exhaust valves. following the preceeding procedU"'.

NOTE: The in

dHill"

C-

chan"",

Co",pany in

___ â&#x20AC;˘

ilf"Cili<<>liom

.... "ny

rillht

11m_

make

withoul

Imp_fa inw,rlnll

<lny

obll""llon 10 ...",,11 IMrn _n "nilS previously oold.

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Section

2002 ENGINE TUNE-UP 188 and 207 Diesel Engines

J I Case

11 K . ' .78826

A Tenneco Company

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2002Â·2

188 DIESEL ENGINE

207 DIESEL ENGINE

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2002·3

SPECIAL TOOLS

TEST STAND CASE PART NO. M20322 BACHARACH PART NO. 65-9340

DIAL INDICATOR

INCH POUND AND FOOT POUND TORQUE WRENCH

COMPRESSION GAUGE ADAPTER BACHARACH 70-0314 (0·558) PART OF CASE M20S20 KIT

A43278 INJECTOR

REMOVAL TOOL

A43277 INJECTOR BORE CLEANER

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2002-4

I ENGINE TUNE-UP I SERVICING AlA CLEANER See Step'

ADJUSTING BELTS See Step 2

REMOVING VALVE COVER

See Sleps 3 thru 5

TORQUING CYLINDER HEAD

See Step 6

CHECKING TOP DEAD CENTER

See Steps 7 thru 28

ADJUSTING VALVES

See Step 29

REMOVING FUEL INJECTOR NOZZLES

See Step 30

CHECKING FUEL INJECTOR NOZZLES

See Step 30

CONTINUED ON NEXT PAGE

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2002Â·5 ENGINE TUNE-UP CONTINUED

CHECKING COMPRESSION

S e e Ste p$ 31 thru 38

INSTALUNG FUEL INJECTOR NOZZLES

See Step 39

CLEANING FUEL LINE SCREEN AND FUEL FILTERS

See Step 40

RETIMING FUEL INJECTION PUMP See Steps 4' thru 49

INSTALLING VALVE COVER

See StlltPS 50 thru 53

ADJUSTING GOVERNED SPEED

See Step 54

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2002-6

ENGINE TUNE-UP PROCEDURE STEP 1 Service the air cleaner. Refer to your Operato,'s Manual.

STEP 2 Adjust the belts. Roferta your Operator' s Manual.

• o

"':~:WOi ~Oi,;lIP "':1\0",001 o~ • • o

Remove breather tube.

FAN . Loosen 8ach cylinder head bolt or nut approximately 1 / 4 tum and then tighten bolt or nut to the &p8cified torquing procedure as listed below and

in sequence

shown above. NOTE: Do not lo-

osen all nuts or bolts simultaneously but loo se n and tighten 8ach individual bo lt a nd nut in th e

proscribed sequence. The bolt or nut is backe d off 1 14 tum 10 break the set of the thread s caused

by heat, high stress and oll:idation. If th is is not done. a false reading is obtained.

Remove valve cover mounting nuts and grom-

1 . Nuts w / hardened weshe n; . torque 95 -105 ft.lbs. 2. Grade 8, 12 pt. hd. bolts - torque 110- 11 5 ft . Ibs. 3 . Flanged nuu • to rque 90 -100 ft . Ibs.

mets.

Remove valve cover and gasket.

Torque rocker arm mounting bracket bolts to insure that the bolts have retained 25 to 30 ft . Ibs. torque.

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2002Âˇ7

Crank engine by inserting a screwdriver into the timing hole in the flywheel housing or torQue tube, and by engaging the ring gear teeth with the screwdriver, align the timing pointer with the 1 ()O BTOC mark on the flywheel.

Remove the push rod.

Com pre.. exhauat valve spring on number one cylinder by using a screwdriver. Tum the rocker arm adjusting screw on number one cylinder intake valve inwards to take pressure off the push rod .

Pu'" down on the number one cylinder Intake velve .pring and at the same time push the rocker arm assembly rearwards,

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Valve keepers removed .

Remove valve spring seat. NOTE: Keep valve s. .1 in place to prevent vatve from falling through valve guide if the piston is moved too far .

Remove velve spring retaine r. Install dial indicator on end of valve stem with valve resting on top of piston .

Remove valve spring.

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""'·9

Cftlnk engine clockwise until dilll indiClitor hand flOpS moving . Reset Indator to uro.

Remove valve stem ...1 from lower valve stem

groolle.

C •• nk engine cloclrM.. until .01 0" mow. on the dJeI indIcator. Scribe II mark on .... flywheal In line with timing pointer. SCRIIIE MARK

-"""'.0-.,' p

-- y =-'0

Cftlnk IInglne C()(II1Wr-clockwile past :zero mart on indiclltoruntil.010" ,howton the dill indk:etor. Again. tcribe II mark on die ftywheeJ in rme w ith timing pointer. 1011811 the apring ..at.

STEP 19

-- .,;\ -

Hilt the diatance betwe«l thlt. two acribe marlu on the flywheel will be the top

d. ad center (TOC) .

''s CR IIIE MARKS

TO CYUNDER

""'" ~COILEND

C<O'W OAM"NG

Install die spring with the damping coil end on lOp of the eyUnder heed. S_ in ..t .bow.

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2002-10

Install the spring retainer. PUSh back the rocker arm assembly.

Compress valve spring using a screwdriver and install a new valve stem seal In tha lower groove.

Keeping the valve spring compressed. install the valve k_pers in the upper vaNe stem groove. Remove screwdriver and tap end of valve stem to seat keepers.

Install the push rod.

Rele.M rocker arm assembly and POSltlon push rod beneath rocker ann adjusting screw.

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2002·11

Check Ind IdJust the Intakl and exhlu$'I Ylllves al pointed ou1 bV the arrowl below. Tappet CI.. rance

• Inuke V.eve•.012" exhault Valve•. 014"

Remove Ind check elch full injector. Refer to Section 3013.

STEP 31 Perform a compression test on each cylinde, ba· for installing fuel injector. There ere two methodl of checking compres· sion pre•• ure - the cranking m8thod and the 8ngine running method. The engine must be at openll'ting temperature for 8rther method used.

FANe) NO . 1 TOC COMPFIESSION STROkE

C,.nk the engine ontl compMte revolution and align the timing pointer with the TDC mart!; on the flyWneeL Chedt and adju5t the intake and elilhaust velve. as pointed out by the .rroWI below. Tappet Clearanee

A. CRANKING METHOD· Remove all fuel injectors. 8 . RUNNING METHOD • Disconnect high

pressure fuel line and leak-off line from No. 1 injector. Routa fuel from the.. lines back to fuel tank or clean container. Repeat for each cylinder.

CAUTION Befofecranklng engine. ma"e Su,,' .?II Ol'",."rmll control,. IIU'

Dralles a,,, aIm lied

~e(

"""tf.11

.lnrl wheds ,1,e secu,ely

. Intake Valvo • . 012" Exhlust Vllvel .014"

•

FANe) NO. 4 TOC

COM~RESSION

STJItOICE

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2002-12

STEP 36

Clean cylinder head injector bore u"ng bore cleaning tool A43277.

Secure gauge adapter with an origin.1 injector clamp .... mbly and spacer.

Always tum tool clockwise. Counter-clockwise rotation dulls tool. Blowout with compreued air.

Connect Case No. CO-504 compression gauge to adapter. NOTE: Take several compression readings on e.ch cylinder using vent valve button to relieve gauge pressure.

In.stall Bacharach 70-314 (0-568) comprnsion gauge adaptar.

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STEP 37 It is very important that all cylinder presaurea be apprxomately the same. See chart for allowable compression pressure variation.

If compression is greater than normal. carbon deposits are indicated. If reading il below normal. leaking valvel or excessive ring clearance is indicated. NOTE: To make a aimple test when a com-

preuion leak is indicated. squirt a teaspoon of oil into cylinder and recheck compression. If pralaure rises to near normel. compression loas is plJSt the rings. Very little change in compression Indicatea leakage past the valves.

Squirt a few drop. of clean engine oil in each cylinder head Injector hole to provide lubricant for carbon dam at lower end of injector when being installed.

ENGINE SPEED

CRANKING RUNNING

APPROXIMATELY 200 RPM 800 RPM

InSUIl fuel injectors.. Ref.r to Section 3013.

Refer to Section 301 0 &. 301 2 for cleaning and servicing the fuel filters and syatem.

NORMAL COMPRESSION PRESSURE

ALLOWABLE VARIATION BETWEEN CYLINDERS

400 PSI-

25 PSI

480 PSI-

20 PSI

'NOn: A .. ~ REDUCTION IN PSI MUST aE AllOWED FOR EvERY 1000 FT. ABOVE SEA LEVEL.

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2002-14

Crank engine clockwise until TOC mark on flywheel is in line with timIng pointer a â&#x20AC;˘ â&#x20AC;˘ _n through the flywh_1 housing timing hole.

Crank engine counter-clockwise (as viewed from the flywheel endl past the specified pump timing: then crank engine clockwise until the timing pointer is in line with the specified pump timing mark on the flywheel. This procedure will remove the slack from the valve train and will insure correct pump timing. NOTE: Refer to engine data decal on engine valve cover or Operator's Manual for specified fuel pump timing.

80th push rod. of No_ 1 cylinder should be loose when No_ 1 cylinder is on TOC of compress/on stroke. If both push rods are tight. crank engine 3600 and again check push rods.

Remove the timing window cover from injection pump.

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2002·15

STEP 45

STEP 47

TlMJNG MA.RKS f-t-+-'e~

TIMING M',.,S

Timing maril.s aligned for proper timing.

Check t iming marks in timing window of in· jection pump. If marks are not aligned. pro-

ceed to next step. If marks are in line. the pump is in time.

Torque pump mounting nuts 35 to 42 ft. lb • .

Loosen pump mounting nuts. Move pump toward or away f rom engine until timing marks ate aligned. NOTE: To advance timing, move top of pump aw ay f rom engina. To retard pump

timing. move t o p of pump toward engine.

Install timing window cover on injection pump.

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2002-J6

Inatall valve cover gasket.

In.tllil the breather hose.

In.taU valve cover.

Chedt and adju.t the engine governed speed II' outtined in Section 3012.

Torque retaining nuts 4 to 6 ft. Ibs.

NOTE:

n..

c- c.mpo..y -...... ,... !IsM

In dnig.. .. .... ~ 1ft _1ff ..1_ "I ... y obli9"1184o ,. h"'all J ...... en unlit p ..... iou<ly sold.

lim.

........

wi","""

1,""_",,,,,,, ...... rri"lJ

""1'

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Section 2015 CYLINDER HEAD, VALVE , TRAIN AND CAMSHAFT 188 and 207 Diesel Engines

J ICase

AM 9Â·788311

A TennecoCO'l'lj)aflV

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2015-2

TABLE OF CONTENTS SPECIAL TOOLS ... .................... .. .................... ..... ................ ................................................ ... . 3,4 SPECIFICATIONS FOR TOOLS WHICH MUST BE MADE ......................... .......... .. ....... ........ ....... 5

CYLINDER HEAD Cylinder Head Assembly ....... ... ................... .... ............... ......... ................. ..... .............. .. .. ... 24.25 Cylinder Head Inspection ... ........................................ ..... ........ ......................... ..... ............. 13, 14

Cylinder Head Installation ........ .. ................................................. ............... ....................... . 26.27 Cylioder Head Removal ... .... ............ .............. ............. ................................................... .. ... ....... 6 Cylioder Head Torquiog . Cold or loitial Torque ..................................................................... 27 Cylioder Head Torquiog • Hot ....... ... .. ............. ........ .......... .......... ............................................ 35 Diagoosi. of Various Valve Bluing Patterns ......................................................... .......... .... 21-23 Expansion Plug Replacement . .... ......................... ............ ....... .. ........ ....................................... 16 locating Top Dead Center ........... ............... ........ ................ ...... ....................... ............... ........ 33 Manifold •• Water Pump lind Fuel Injectors Installatioo ...... ......................... .. ...................... 31 ·33 Refllcing Valves and Valve Seats ...... ......... ....... ...................................... ........ .................. ... ... 20 Rocker Arm Assembly .......... ............ ............. .......... ........... .......... ............ ...... ............ ....... 28-31 Valve Bluing .. ....... ................. ......... .. ................. ................................................ ............. ........ 20 Valve Guide Replacement ............... .......... ................. .......... ............................................ .. 14,15 ValV9 Inspection ................................................................................................................ 17· 19 Valve Seat Inspection .............................................................. ... ........... ............................ 17-19 Valve Seat Replacement .......... ...... ............... ........ ........... ....... ................... ... ....... ...... ........... .. 19 Valve Tappet Adjustment · Cold Setting ............................................................................ 34·36 Valve Tappet Adjustment - Hot Setting with Engioe Stopped ................................................. 37 CAMSHA" Backlash • Camshaft to Crankshaft ................ ..... .................. ............................................. ..... 63 Backlash • Camshaft to Idler Gear ............................................................................ .............. 57 Backlash • Idler Gear to Injection Pump ...... ........... .. ........ ............ .... ...... ..... ......... ....... ........... 58 Bushing Replacement - Front ....................... ... : ...... ......... ..... ..... ......................................... 45,46 Bushing Replacement· Intennediate .................................................................................. 46·47 Bushing Replacement · Rear ............. .......... ........ _ ............................................................ 47-49 Camshaft· Assembly ............. .. ..................... .... .................. .. .. .. ................ ... ..................... 51.52 Camshaft · 'ostallation ........ ...... .... ..... ......... .... ........................ ............... ........................ ... 53·61 Camshllft • Removal ... ..... ......... .. ..... ...... .... ... ...... ................ .... ..................... .. .... .. ...... ........ 38-44 Idler Gear - lospection ............ ........ .............. .... ................ ... ... ................ ... ......................... ... . 55 Idler Gear· lostallatioo .... ......... ......................................................................................... 56.57 Valve Ufters - lospection ........ ........... ................................................................................ 49,50 Valve lifters · Replacemen t ............................................................................................... 49,50

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2015..J

SPECIAL TOOLS

A43112 VALVE GUIDE REAMER

A432n INJECTOR REAMER

A43278 INJECTOR REMOVAL TOOL

ASAE TACHOMETER DRIVE REMOVAL TOOL {SEE PAGE 5j

NON ASAE TACHOMETER DRIVE REMOVAL TOOL (SEE PAGE 5)

THERMO MOUNTER . MOOEl "C" ELECTRONIC OESIGNS. INC. 5164 N. 62ND STREET MilWAUKEE. WIS . 53218

,@~ VALVE SPRING COMPRESSOR

~ 0@@

A41103 CAMSHAFT BUSHING TOOL KTT

M20419 CYLINDER HEAD WRENCH

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0- TO 5 ~ BOllE GAUGe OR INS loe MICROMETER

FOOT POUND TORQUE WRENCH

!5 ~

MICROMÂ£TEA

OEPTH MICROMmR

VALV!" SII!"AT REMOVAL TOOL

DIAllNOfCAroft

SPRING TESTeR

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2015-5

SPECIFICATIONS FOR TOOLS WHICH MUST BE MADE Tachometer Drive Removal Tool ' 18~

1 /4~

NON ASAE TACH OM ETER ORIVE REMOVAL TOOL

1-7 / S" 0 .0 . X 1 路 6 /S~ 1.0. X 1_7 / 8" LONG BUSHING

TACK WELD

X l H ROLL PIN

1 / 4~

DtA .

~'".'"''' BOLT HEAD AND THREAD END 3/4 ~-20

U.N. EXTRA FINE

OtA. HOLE

lI S~

ASAE TAC HOMETER DRIV E REMOVAL TOOL

TACK WELD

3/4~-'O N.(~~---

' 路718 0 .0 . X ' 路 S/ SH t.D . H

l 路71S ~

LONG BUSHING

7 / S" -1S NS- 2A

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201~6

CYLINDER HEAD RECONDITIONING

207 DIESEL ENGINE

188 DIESEL ENGINE

Removal

Remove fuel injectors. Refer to Section 3013.

Remove valve cover.

STEP 2

Remove breather tube.

Remove vllve cover gasket.

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2015-7

Remove fan . fan spacer (if pulley.

equip~)

and fan

If engine is equipped with one piece timing cover. remove outer bolts secured to cylinder head. NOTE: if a stud and nut is located at point " A", the water pump must be removed to ,emove the innet soeket hd . bolt in the housing.

Pull the front of manifold from the front stud, swing the manifold upward and pull manifold off of rear stud and away from engine.

Remove exhaust manifold gasket.

Remove intake manifold retaining nuts.

Remove the exhaust manifold retaining nuts, washers and ciamps.

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2015-8

Remove intake manifold .

Loosen front and rear rocker arm assembly bracket bolts.

Remove intake manifold gasket. Remove brackets and boits.

Cytinder head ready for rocker arm disassembly.

ROCfI:er arm and spring will fall off each end due to spring pressure.

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2015-.9.

Remove remaining three rocker arm usembry brKket bolts.

Rocker erm aQ8lTlblv and push rods removed.

Looaen valve cover nud and nut UMmblles Remove rema ining rocker ann .... mblV. NOTE: ne the alSembly together to prevent partl from falUng apart.

u~ng

M2041"9 cyllndar head wrench.

Romvve v.tv. assemblies and

c~,

mounting stud and nut

~lhers.

Remove push rods.

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2015-10

Loonn cylinder head mounting botta.

.".

Remove cylinder head mounting bolta

Remove cytinder bench.

end plaC41 on WOTtI

and washÂˇ Cylinder head removed .

Cytinder h..d ready for removal.

Remove cyNnder hud guket.

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2015Âˇ11

Cap the end. of fuel lines.

Ramove valve keepers.

Cylinder head on work bench

Remove spring ratainer.

STEP 31

Compress valva springs with a spring comÂˇ pressor.

Remove valve .prlng.

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2015Âˇ12

Remove spring seat.

Remove valve.

Remove valve stem seals.

Valve asaemblies removed.

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2015-13

Cylinder Head Inspection

Wuh. clean and inspoct cyiinder head. Use rotary

wire brush to clean around and down into the valve ports. Clean carefully all machined surface areas. ""ith emery clOth. removing all gasket material. carbon and rust from cylinder head.

IMPORTANT: If the cylinder head has been reo surfaced, the must be cheeked so as to prevent contact. Refar to Staps 65 and 66.

STEP 40

Lay a straight edge across the bottom of the cylinder head from comer to comer. Try to g9t a .006" feeler gauge under the straight edge. The maximum limit for head warpage is .006". If warpage is greater than .00&", the cylinder head must be replaced or resurfaced. A minimum head thickness of 3.96S" must be maintained 11 cylinder helld Is resurfaced.

IMPORTANT: If the cylinder head has been resurfaced. the valve recession must be checked alISO. Refer to Sleps 65 and 66.

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2015-14

STEP 43 SORE GAUGE

Check bore gauge with a micrometer. If the diameter is greater than .3449" at any point, ",place the valve guide. If the inside d iameter of the valve guides is less than .3449", proceed to valva and seat inspection. Refer to Step 63 .

Chock valve guides with an expandable bore gauge in three places as illustrated in the inset.

Valve Guide Replacement

To replace valva guides, place the cylindet" head in a hydraulic press. NOTE: Always press guides from the top, through the head.

Valve guides must protrude .875 above ttle cylinde r head. Fabricate a bushing (.688" minimum 1.0 . x .875 " long) and place over the valve guide. The bushing will aid in obtaining correct guide protrusion. M

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2015Âˇ15

U.. a hydraulic press to push valve guides into heed.

Ream new valve guides to .3429/ .3439" ulfng A431,2 reamer.

Press valve guides into head until hydraulic press makes contact with fabricated bUlhing.

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2015-16

Expansion Plugs Replacement STEP 52

If the ellp4naion plugs need replacing. they must be drilled and pryed out.

Install a n&wtop expansion plug to depth shown.

1.7sr

'r '0

Install a new end expansion plug until it is seated and then strike a blow with a hammer to cause ellpansion.

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2015·17

Valves and Valve Seats Inspection STEP 53

HEAVY CARBON AND VARNISH DEPOSITS

Clean valves with a fine power driven wire brush, being careful not to scratch valve stems.

STEP 64

NOTE: CLEAN ANO REFACE VA LVeS IF THI S CONDITION EXISTS OR REPLACE V ALVES .

INSPECT THE VALVES FOR THE FOLLOWING CONDITIONS .

Thi s condition is usually caused by worn valve guides or bad seals o n Ihe valves, allowing oil to pass by the valves . Low opera ting temperature is still another cause or worn piston rings and sleeves will allow too much oil to r each the combustion chamber.

~_=o;:;;;N;';';';';O;;';A;':':':;S~"~M~::::::JOJl]

IOU

NOTE: REPLAC E VALVE IF THIS CONDITION EXISTS.

This condition can be caused by lack of lubric ation, plugged water passages Or operating the engine under continuous overload at excessive RPM.

RUST OR PITTING ON VALVE STEM

NOTE: REPLACE VA LVE IF THIS CONDITION EX ISTS. _ _ _ GROOVE IN VALVE FACE

Thi s condition can be caused by using poor quality engine oil or fuel and by improper engine storage. PITTING IN VALve FAce NOT£: REFACE OR DITION EXIST S.

REPLACE

VALVE

THI S CON·

This condition can be caused by abrasive s enter· ing the engine through the intake syste m or not servicing the air intake system regularly .

II 0I NOT!. REFA CE O R REPLACE VALVE

IF THI S CO N.

OITION EXISTS. FINE PITTING

This condition ca n be caused by using poor Quality engine oil or fuel.

NOT£: THI S IS A NORMAL CONDITI ON

Small amounts o f very fine pitting may be found on the surface s of the valve face or seat after the valves are cteaned. This condition is normal and will not affect engine performance. This fine pitting is caused by a normal oxidation process and can happen on any engine during the run-in period. It is not necessary to grind valves or seats if this f ine pitting is found , since p itting will generally recur after the engine is run for a few hours.

DEEP BURNED VAlVE FACE 0"';'" NOT£: IF EITHE R OF THESE REPLACE THE VALVES .

VALVE HEAD

CONOITI ONS

EXIST.

These conditions a re usually caused by running the engine under excessive loads a l h igh engine temperature, grinding valve face too thin or improper valve g rinding.

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'2015-18

STEP 54 (CONT)

WORN RETAINER GROOve

WORN STEM TIP

NOTE: IF EITHER OF THESE REPLACE THE VALVES .

CONOInONS

EXIST.

Check exhaust vatve stem diameter at three point. along the s tarn. If stem diameter is 1811$ than .3389 ", the valve must be replaced .

. 3389"

Check intake valve stem diameter at three poinu along the stem. If Item diameter is len

. 338' ~

thlln .3;J99", the valve must be replaced .

. 3399"

. 3l99 ~

EXHAUST VALVE

.3399 "

INTAKE VAlV I!.

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2015-19

STEP 57

STEP 66 INDICATOR

m .",e'. HOLDER

EXHAU ST V ALVES

! .005-

,,'\.

;::!=!::======

INTAKE VALVES WITHO UT

REPlACEABLE

"AU .

Place the valves in the cylinder head and check valve head recellion . If the valve head Place the valves in a "Vee" block type holder with a dial indicator. Check valve face and stem run-out. Run-out must not exceed .. 002" on either the valve face or stem. Replace valves if run -out exceeds .002" .

has receded more than .0015" below head sur-

face, the valva andl or valva insert must be replaced to insure aqual compression

ratio

between cylinderâ&#x20AC;˘.

Valve Seat Replacement

Remove exhaus t valve seats with a seat remova' "tool or have the seats machined out. NOTE: Navar attempt to ,emove valve seats with a c ente r punch, cold chisel or pry bar.

Clean the recess in the cylinder head. Place new valve seats in dry ice to shrink them for ease of installation.

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2015·20

Refacing Intake and Exhaust Valves and Valve Seats STEP 60

£ 4t-~~=:4:5;'~V~A~L~V~E== VALVE 8< SEAT GRINDING ANGLES

II' MARGIN " A" ON VALVE IS lESS THAN 1 / 2 MARGIN "8" ON A NEW VALVE. REPLAC E VALVE .

rF,==========

Remove the valve and inspect the contact area on the valve face and seat. The bluing will have been removed from the valve face where it made contact with the seat.

SEAT ,(;50 SEAT 45"

-( ~.

EXHAUST VALV E

STEP 63

45° VALVES

INTAKE VALVE

Use a preCISion seat grinder. Take very light cuts with the grinding stones so that just e· nough metal is removed to end up with a good .smooth seat finish .

Correct refacing of valves and seats will provide a bluing pattern as shown . If bluing pattern is other than the pattern shown, refer to diagnosis of various bluing patterns on Pages 21 thru 23.

Apply a small amount of valve bluing (Prussian Blue) on the valve face. Install the valve in the head and rotate the valve on its seat.

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Diagnosis of Various Bluing Patterns 45' INTAKE OR EXHAUST VALVES If valve contact IIrea on seat

......

Use

45° stone to raisa and

......

widen contact area

looks like this (previously ground

seat!.

SEAT CONTACT AREA ON VA l ve TOO lOW

'i, CONTACT AREA

If valve contact area on seat looks like this.

......

Use II 45 0 stone to raise contact area.

--+

Use II 45° stone to lower and widen contact area

.......

The valve and valve seat must be replaced since additional grinding will not alter the lower contact point.

~4+---

NOTE: This contact pattern will also be found on intake valves without replaceable

seats. If valve contact area on seat 10oks like this (previously ground

seatl.

SEAT CONTACT AREA ON VALVE

TOO HIGH

~~\ii~~ CONTACT AREA

If valve contact area on seat looks like this.

http://stores.ebay.com/UsefulCDs NOTE: This contact pattern will also be found on intake valvas

without replaceable seats .

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2015Âˇ21

sa a 60 0 narrowing stona to arrow lower contact area ineased by 45 0 stone.

Check that valve head has not _ receded more than .005" below cylinder head surface.

If valve head recedes or protrudes more than .005", refer to Steps 65 and 66.

se a 60 0 narrowing stone to ise and narrow lower contact

Check that valve head has not _ receded more than .005" below cylinder head surface.

If valve head recedes or protrudes more than .005", refer to Steps 65 and 66.

Check that valve head has not receded more than .005" below cylinder head surface.

If valve head recedes or protrudes more than .005", refer to Steps 65 and 66.

Ie a 300 narrowing stone to Irrow upper contact area ineased by 45'" stone

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Diagnosis ,o f V ar ious Blu ing Patterns 45~

2015·2

INTAKE OR EXHAUST VALVES It valve contact aftlaon s~t !lIDks l ike this (pFaVioLJsl'f ground

Us~ a 4<5" stolle to wfod en oontaet area

1':11"

and

"he a 60" I'IS rr owing 1I1one to Nlnow I'o wer contact arCa in· C;re~iSed

$eM],

bv 4S Q

Chec k t hat: valve hBad has !'lOt

s ~orte_

H v~llIe head reeed~ or p.rot rud es mDre t har

,005 '., refer to Steps

ami 6-6.

S-EAT C O ffTACT AREA 0 ' TOO lOW

VALVE

If v.IIIVG Il.Ql'ilaQ\ 10011;$ IlII;e- t h i s,

ar6~

on seat

1J Sit

tllct

are~ ,

45" SJtone to

r ~i118

con-

U:!ie a 50" nlllrrowing st one to raise IIIl'Id narrOw lower e Ol'lt~.c t

- . C heck t h~t valYe tKl.lld h <ls r\o t ~C>eded

~Mn

Io.w cvll noer head

IItga.

,005" De·

v~l ve head ra~ de~ Or pro1rudeB mOrn t h~ 1

,005". reltjr to S lep~

~u rlace,

'II ~

and 66,

N OlE: 'This COl'ltact p attern will ai m be t'aund 01'1 int ake valveli without MPlaoellbl'e sil'ats,

I f va ~ye contaGt a~1I on said: 10 o k.s like ~I<W$ ~ pre'oliouslv ground

Use a 45 0 s tonlt tu luwwe.. and w iti9n c.orrtact arMl

~Ilt~,

SEA.T CON TAC T AREA 0 N VA ~Ve

roo

HIIJH

I'. volv& contact are@ on $e8t Iook5 like 1his"

The v BIII'"e an d valve s.at m ust be

replaced

s ince.

addiiiOf1.1

11 rin ding will nat altar the- low e r con tact Doi nt_

alsa be ta u n,d an il'lt8~e val ve:!! w~th (lU"t nJ pl\mBmb!1t Bemts.

USB a ,3~ narrowil"Lg $1.OffIe to nBHOW upper cor\tact arBB inl::iro::aSllld by 450 Sltooo

Checlt 1hat valYe hEtad "'IDS n ot receded more than ,005," hel'ovv .cVlinder hlmd sLJrfilOC ,

It VB l w h",~d rec e(le, or pratrl,ld~.s mQM t hsi .005". re fer 10 Steps 6 ! 1!I'I(l66_

2015Â·22

"''''''''''1

If valve COntact area on seat 10' _ oks like this (previously ground seat).

Use a 45 0 stone to tact area.

If valve contact aTea on seat 10- _

The valve and valve seat be replaced since grinding will not alter wer contact point.

SEAT CONTACT AREA TOO NARROW

'i',

CONTACT AREA

oks like this

NOTE: This contact pattern will also be found on intake valves without replaceable seats.

If valve contact area on seat

Use a 300 narrowing

If valve contact area on seat 10- _

Use a 300 narrowing

10-

oks like this (previously ground seat).

SEAT CONTACT AREA ON VALVE TOO WIDE

CONTACT AREA

oks like this

NOTE: This contact pattern will also be found on intake valves without replaceable seats.

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'0-

Check that valve head has not

receded more than .005" below cylinder head surface.

valve head

racedes

Or protrudes mora than .005", refer to Staps 65

and 66 .

...

,,' 0-

'0 _

, __ _ . 0 ' _ , " , ,~.

Use a 60 0 nsrrowing stone

rai$e lower contact area.

'0 -

.......

.... . '---:::-:"",""

Check that valve head has 00' receded more than .005" below cylinder head surface.

,.". ~-~ - . - -

.. - ... .~

If valve head r&Cedes or protrudes more than .005", refer to Steps 65

and 66.

to _

Use a SOO narrowing stone raise lower contact area.

'0 _

i j

Check that valve head has not receded more than .005" below cylinder head surface.

If valve

head recedes

or protrudes mora than .005", refer to Steps 65

and 66.

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The correct exhaust valve con· tact area on seat will provide a seat width of .0608" to .0962 "

TH!S IS TH E CORRECT SEAT CON· TACT AREA ON VALve

//'

The corre ct mtake valv tact area will provide width of .0704" to .1057

•

CONTACT AREA

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2Q15-22

If val\ll8 contact area on seat 10- _ _ ob like this fpraviGu:!IJV gmund

Use a 45 Q smne to.

tact

in~~~,

_ con.

arll~,

se-"tl-

Ghec~ 1t1at ~8tvil hond hills not r,e cedao mere th~11 _005" below c;yllndor hoad surlace.

If valive hQd r etechls or protrudes mare 1ih8n .005", r.,f8~ to Steps 65 rld 66,

The va .... e ami "Dive seat must be replBioed ~i.l'leen<fditiOIlill grindirlIJ will not alter the 10W~ r contact po int.

If valve conUict 8ffl on seat 10 oks li~e 1ihja jW~ IOU$1iy grourld

U B8 a 30~ narrowing stono to _ _ l ower upper cont8.c t ama.

------

U~c a 60" [)an-OWing 51.ooe to

r~ iUI lower co(ltllct are '

~o~t].

Check that val\!'B heed h8s not l1lecdml mQra thlan .005, ~ below , c;ylind~, he~d wrtlllCU.

---

If valve he&d recedes o t protn~de$ more than ,005". refer to Steps 65 an,d 6S â&#x20AC;˘

.005~ SÂŁA"J co NTAC'T AREA ON V"" L'I'E TOO WIOE

H ... alva 'G ontact ob IJ~ this

8rea

on SENIt 10 '

NOiE: This cont~ot pfOl1ert'l will also bl;!' f ound on intake valive~ without replaceable saatB.

U S8 a 300 nilrr<IWlnfi slone .~ _ 10 ..... r UlllP4lr contact arH.

UI& a 6~ narrowing stone t o r~ise i:Owi)r COl'ltlitCt ~rea.

C heck. that 10'81"9 h.aad h ~~ not rue.dud mOr& titan .005 billow C\, lind&r hella s u rfaeo_ 0

If va 1"'8 head ~Bcede!t Or prohude~ more than _005", refer 10 Ste;p$ 65 and 66.

conseat

2015-23 Interference angle '

_ c onact

refa . eX.haust valv:l;g of intake and will provide a a,:d .valve seats a~gle. This angle .lnterference sInce it , Ismc 'd. IS . import an t and helps seat th lIttmg carbon e valves.

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2015-2:1 1IlI1S IS liME. CORRECli SEAT 00 TACT ""JIEA. ON VA:l.ViE

The corN!ct e~l1au$t V8lvlI eon· til1:'t area on II'Bst wi II provide a $e~t ..... Ictt~ Of .06011 ~ to .0962··

The eoneet inmlle

1oI&1V,9

cOn-

pwvide .a se.-l width c)f ,0704 to ,1 Q67N

teet _

w[il

COrrect rdllcing of int;ill{~ lind exh 8.~st v~ IV!!$ and val...-e seats wILl ,p rovide a 1 0 inteTle.renca angle. T tlis angle is imp ortant sinoo it illds in el,ltling carbon

alld help$

~e~l

the

v~l ves.

2015Âˇ24

Cylinder Head Assembly and Installation STEP 64

.,.

Install a velve into the cylinde r head one 8t 8 time and perform s teps 65 and /o r 66.

Check for valve protrusioo . Piece II straight edge 00 the valve and measure the distaoce between the . traight edge and the cylinder head, using a feeler gauga. If protrusion is more than .005". TefeT to pages 21, 22 and 23 fOT proper valve and seat g ri nding .

Check for valve recession. Place 8 Itraight edge over the valve and measure the distance betweeo the straight edge and the valve head , using a feeler gauge. If recession is more than .005 ", replace the valve and/or valve seat.

After valve protrusion and recassion have been checked and corrected, lubricate velve stems with HDM 1130 oil befo re installing into cylin Âˇ der head.

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2015-25

STEP 68

11'-.,.

CHECKING SPRING WITH ""NG " " "

DAMPING COil

Install valve keepers on the top valve Ilem 9roove. NOTE: Always install new valve keepers when new valves are installed .

tnmll spring seal. spring (damping coil. towards cylinder headl and spring retainer, NOTE: Check spring for broken colla and for proper specifications listed in Section 1026 or 1027. using a spring tester.

'£ ~ ~~"'"',-, '~,;.; .

•

• •

Remove

the

• spring

compressor

and

tap

valve stem to seat keepers.

Compress valve spring with • spring comprenor and install valve stem MIll in lower

atem groove.

Install the other intake and exhaust valv81, following the preceding procedure.

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2015Âˇ26

Before installing cylinder head on block, clean the injector bores using A43277 reamer.

Carefully slide the cylinder head Oller the cylÂˇ inder block and lIalve cOlier studs. down on the aligning dowels until resting on the block.

STEP 74

C"",'~''"

c,u.,~''" PART

HEAO

HEAD GASKET WITH FIRE fliNGS GASKET

Install a new cylinder head gasket and check to see that all gasket holes align with block holes and especially that the 1/4" water hole of gasket is towards the front of the block. NOTE: Refer to Sections 2025 or 2125, sleeve protrusion, if you are experiencing head gasket leakage problems.

Install washers and valve cover mounting nut and stud assembly over the valve COlier studs.

Install cylinder head bolts and washers or nuts.

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2015-27

Check pus h rods for wear and straightness bafore installing into cylinder head . Coat push rods with HOM #30 oil .

Coat bolt threads. washers and underside of bolt heads or nuts (whBre used) with HOM #30 oil. Torque all cylinder hBad bolts and nuts (on to stud) using a torque of 50% to 70% of final torque listed below and in a sequence as shown in inset. Repeat torquing sequence and bring nuts or bolts to full torque.

1 . Nuts w / hardened washers-torque 95-1 05 ft. Ibs. 2 . Grade 8. 12 pt. hd. bolts - torque' 1 0-115 ft . Ibs. 3. Flanged nuts - torque 90-100 ft . Ibs.

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2015-28

Rocker Arm Assembly STEP 80 Flush the rocker arm shafts to remove any residual material. Inspect shafts for worn spots on the bottom side of shaft. Replace the shafts if a wom condition e;ltists. Coat all pans with HOM #30 oil.

IMPORTANT: 8efore installing the rocker arm assembly on the cyfinder head, the location of the special drilled bolt must be determined for

rocker arm lubrication . Prior to engine serial number 2072089, the drilled bolt must be located in the center rocker arm mountfng bracket. After engine serial number 2072089, the drilled bolt must be located in the rear rocker arm mounting bracket.

Install bolt and washer (drilied or undrilled. see Step 80) into the canter bracket.

Install center rocker arm bracket on cylinder head.

SHORT ENO _ ___ I

'\CUT OUT

Oil HOLES

Install the front rocker arm shaft Into the intermediate bracket. NOTE: The front shaft is installed with the short end of the shaft (from the cut-out) towards the front of the engine. The rear shaft is installed with the short end of the shaft {from the cut-outl towardl the rear of the engine. On shahs with oil holes drilled only on one side, point the oil holes downward and on shafts with oil holes drilled on both sides, align the holes in a horizontal plane.

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2015-29

PLUG8;,,' ,IDENTIFIED

"0"

USE THIS

A~':~~~!'~N'~ C~~

WITH THIS ROCKER

Install spring .

THIS ADJUSTING SCREW ROCKER ARM .

arm. NOTE: left hand is determined in this manner: when standing on

Install 8 left hand

the push rod side of the cylinder head, the rock Âˇ er arm will slant away from the valve towards

the left.

Install a right hand rocker arm on shaft with correct slant of arm in correct position as shown. NOTE: Failure to use the correct adjusting screw with designated rocker arm. will result in lack of lubrication to the valve train. Rocker arms are completely interchangeable. See above inset.

Install end of shaft assembly into the center bracket and install bolt and washer into the intermediate bracket.

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2015-30

Assemble and install the rear intermediate shaft assembly following steps 83 thru 87_

Install a left hand rocker arm.

o Install rear bracket on shaft. Install a right hand rocker-arm on Âˇshaft.

Install a spring.

'nstall bolt (drilled or undrilled, see .Step 80) and washer into the rear bracket_

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201~31

Assemble and install the front rocker arm as· sembly. following step. 89 thTU 93. NOTE: The front bracket mounting bolt is always undriUed.

ComP'eted rocker arm assembly.

. '"

•

:!".

Torque rocker arm bracket bolts 25 to 30 ft. Ibs,

...

-- -*.:;,

!f'

,,,.;-

"- Manifolds, Water ~

-:;"' ___

Install a new intake manifold gasket.

~ump

&. Fuel Injectors Installation

C·~

• :." ..•

Install the intake manifold.

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2015-32

STEP 99

Torque the intake manifold nuts and washers accordingly: on aluminum manifold, torque nuts 30 to 35 ft. Ibs., on cast iron manifold. torque nuts 25 to 30 ft . Ibs.

Install retaining clamps, washers and nuts.

Torque nuts 25 to 30 ft . Ibs.

Install a new exhaust manifold gasket.

STEP 101

Install the exhaust manifold by holding front in raised position and installing rear of manifold on rear stud. Lower front of manifold down and install on front stud .

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IMPORTANT: Apply Loctite Primer"T" and Loctite #271 (Case 817429 and 817423) on water pump housing inner socket hd.capscrew threads to prevent capscrew backing out into impeller. Install capscrew and torque 35 to 42 ft. Ibs.

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2015·33

Install water pump, pulley. spacer (if equipped)

and fan . Refer to Section 2055 for installation.

Install the fuel injectors. Refer to section 3013 for injector installation. NOTE: Squirt a few drops of HOM 1130 oil in each cylinder heed

injector hola to provide lubricant for carbon dam at lower end of injector.

Locating Top Dead Center

()

• Crank the engine by Inserting a Screwdriver into the timing hole in the flywheel housing Or torque tube and by engaging the ring gear teeth with the screwdriver. align the timing pointer with the TOC timing mark on the flywheel.

Check push rods on the number one cylinder for

loosene$$. If push rods are loose, the number one cylinder is at TOe on the compression Slroke. If push rods are tight. crank engine one com-

plete revolution end ·align timing pointer with TOC mark on the flywheel.

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2015-34

Valve Tappet Adjustment-Cold Setting

•'<:::

Check and adju.t the intake and 8lChault valves

After the valve tappet adjustment (cold setting)

as pointed out by the arrows below.

is complete, start and run the engine. Check that the engine oil pressure gauge is register· ing in the green zone . Check the rocker arms

Tappet Clearance Cold · Intake Valves .012" Exhaust Valves .014"

FANe) 3

to insure that they are receiving oil. NOTE:

Squirt HOM #30 oil through valve springs to lubricate valve stems before starting the engine.

NO.1 Toe COMPRESSION STROKE

STEP 110 Crank the engine one complete revolution and align the timing pointer with the TOC marl< on the flywheel. Check and adjust the intake end exhaust .valves 8S pointed out by the arrows below.

Shut the engine oft and Install valve cover gasket and valve cover.

Tappet Clearance Cold· Intake Valves .012" Exhaust Valves· .014H

FAN 4

() NO . • TOC COMPRESSION STROKE

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2015·35

Torque the valve cover nuts 4 to 6 ft . lb•.

STEP 114

BOLT TORQUE SEQUENCE

FANE)

Loosen each cylinder head bolt or nut approxi· mately 1 / 4 turn and then tighten it to the speci· fied torquing procedure as listed in step 78

and in sequence as shown in inset. Do not loosen all nuts or bolts simultaneously, but loosen and tighten each individual nut and bolt in prescribed sequence. The nut or bolt is backed off 1 / 4 tum to break the set of the threads caused by heat, high stress and oxidation. If this is not done II false reading is obtained.

InstaU breather tube.

STEP 115 Start and run the engine approximately one hour (under load if possible). to thoroughly

warm up the engine and seat the head gasket. Refer

Aun-in - Procedure,

section

RetorQue rocker arm mounting bracket bolts to insure they have retained 25 to 30 ft. Ibs. torque.

1022.

STEP 116 After the engine has run for one hour, remove the breather tube and cylinder head valve cover. The cylinder head bolts (or nuU) and rocker arm mounting bracket bolts must be retorqued . Also

the valve tappElts must be readjusted . These functions must be performed while the engine

is hot.

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2015-36

Crank the engine until the timing pointer is aligned with the TOe timing mark 0f1 the flywheel. Check the push rods on number one cylin-

sr for looa.n.as. If the push roda are 100". tha number one cylinder is at TDe on tha compression stroke. If the push rods tight. crank the engine one complete revolution and align the timing pointer whh the TOe mark ..2!!...~. f lywheel .

a,.

•

.,.• . '

.'.

:.;,~

'" -","" •

•

~-..

~,f;.

-." .0. •

•

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2OL>-37

Valve Tappet Adjustment - Hot Setting With Engine Stopped r \

STEP 120

6r '

Crank the

engine

one

complete

revolution

and align the timing pointer with the TOC mark on the flywheel , Check B,nd adjust the intake and exhaust valves 8$ pointed out by the arrows below. Tappet Clearance Hot - Intake Valves .012" Exhaust Valves .014"

FANe) 4

Ch6ck and adjust the intake and exhaust valves as pointed out by the arrows below. Tappet Clearance Hot - Intake Valves ,012" Exhaust Vatv.. ,Q14"

FANe) 4

~o .

NO. 4 TOe COMPRESSION STROKE

1 TOe COMPRESSION STROKE

Install the cylinder head gasket and cover, torque cover nuts 4 to 6 ft . lbâ&#x20AC;˘ . Reinstall breather tube.

()

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2015-38

Camshaft, Valve Train and Backlash REMOVAL

Before the camshaft can be removed from the engine, the tachometer drive must be removed.

To remove the tachometer drive, a special tool must be made. Refer to specifications for making special tools. found on page 5.

Screw the tool into or onto the tachometer drive and pull drive from engine.

()

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2015Âˇ39

Remove the tachometer drive from the spacial tool.

Disconnect fuel injectors inlet fitting using the one-hand, two wrench method to miniÂˇ mize damage.

Remove breather tube.

Remove the engine oil pan.

Remove valve cover nuts and gaskets.

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'2015-40

Remove valve cover.

Remove exhau.t manifold by removing front of manifold from front stud, swing manifold upward and remove manifold from rear stud and away from engine.

Remove water .pump & water pump housing. Refer "to Section 2055.

Remove rocker arm assembly.

Remove exhaust manifold ' retaining c iampa, wa.hers and nÂˇuts. Remove push rods.

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2015-41

The valve lifters must be lifted off cam lobes and retained in place in order 10 remove the

Remove cover plata. NOTE: If equipped with one piece water tube and cover plate, remove .

eamahaft. Cut 8 wood dowels (approximately 3 / 8" die. x l' long) and insert into puah rod openings in cylinder head. Push the dowels into the valve lifters hole.

Raise the valva lifters with the wood dowels and retain in place with clothespjns.~. -

Loosen crankshaft pulley mounting nut.

o Remove water tube.

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2015-42

Remove

crankshaft

pulley

mounting

nut.

Remove crankshaft pulley.

Loosen idler gear mounting bolts.

Remove bolts. lock plate. thrust plate and shims.

Using a punch and hammer. straighten out

lock tab on the idler gear lock plate.

Remove idler gear.

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201~3

Remove the idler gee, hub shaft.

Remove timing fuel pump.

gear

cover with

attached

remove the one piece water pump and timing gear housing assembly. NOTE: If a stud and nuJ I" located in place of a bolt at point "A", the water pump must be removed and the inner socket hd. capscrew must be reo moved in order to remove the timing gear housing. If equipped,

Remove two inside bolts from timing gear cover.

Remove timing gear cover mounting bolta.

Remove timing g88r housing gaskat.

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Remove oil slinger from crankshah.

Remove bolts and external tooth washers.

Align holes in cam gear with thrust plate mounting bolts.

Remove camshah from the block.

Camshah removed from block. Loosen thrust plate mounting bolts.

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2015-45

Front, Intermediate And Center Camshaft Bushing Replacement

Using a bore gauge, measure the camshaft busBngs. The bushing must be measured in two places. Take the second measurement 90" from the first measurement, NO TE: If bushÂˇ ing 1.0 . is greater than -' .755", replace the

Pullar installed in bushing to be removed.

bushing.

Insert bushing puller A41 1 03 into the angine block to remove camshaft bushings. NOTE: The crankshaft, cylinder sleeves and pistons have been ramoved for photographic purposes only. These pans need not ba removed when servicing camshaft.

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2015-46

STEP 161 (CONT.) INTERMEDIATE 80. CENTER BUSHINGS MEDIUM WIDTH

FRONT BUSHING

WIOE WIOTH

fORWARO fACE OF BLDCK---

ALIGN OIL

"OLE

-----

PRESS CENTER&. INTERMEDIATE BUSHINGS fWSH WITH FORWARD FACE Of BLOC K,

A~Z

FRONT OF ENGINE BLOCK OIL

"OU

111e camshaft bushing kit Includes three 1 / 2 " medium w;dth intermediate & center camshaft bushings. The one oil hole Is offset to one side and should face towards the front of the engine when installed . Press the intermediate and center bushings fluah with forward face of block and align holes " A " with oil passages in the ' block.

-om PRESS FRONT BUSHING 1 /32 ~ BELOW FRONT FACE OF BLOCK,

The camshaft bushing kit includes a 1-7/32"wide front camshaft bushing, The two oil holes are offset to one side and should face towards the front of the engina when installed. Press the front bushing 1/ 32" below front face of block and align hole. "A " with oil passages in the block. Hole " B" is against blank surface in the block.

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2015-47

Install the bushing on the puller (with oil holes alignedl and pull bushing into place.

Pull the bushing into block bore. Remove bushÂˇ ing tool.

Rear Camshaft Bushing Replacement

To replace the rear camshaft bushing. the enÂˇ gine must be removed from the machine and then the flywheel must be removed.

The rear camshaft cup plug must be removad before the rear camshaft beating can be reo moved from the engine block.

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2015-48 REAR SURFACE OF BLOCK

ONLY ONE OIL HOLE WILL UNE U P

\,~~/s:L,..

o PRIOR TO ENGINE

SI N 20720B9 1 - - 1 _7 / 32"_

.â&#x20AC;˘

Remove cup plug from engine block by inserting a rod into the block and then tap plug out. --19/ 32"

",r

r--

'///? REAR

TWO OIL HOLES WILL UNE UP

ENGINE

S I N 20720B9 AND AFTER

f-, )~

1 - - 1 -7 / 3 2 " -

Install the rear bushing on the puller (with oil holes aligned) and pull bushing into the block. The camshaft bushing kit includes a 1-7 / 32 " wide width rear camshaft bushing. REAR BUSHING WIDE WIDTH

-6 / 16 ~

The 1 -7/32 wide width rear bushing is used in place of the 16/ 16" wide rear bushing prior to serial number 2072089. The two oil holes are offset to one side and should face towards the front of the engine when installed. On engines prior to serial number 2072089. only one of the rear bushing oil holes must line up with the oil hole in the block when the bushing is installed to a depth of 19/32". The other rear bushing all hole will not line up as it i. not required for engine lubrication. On en. gines prior to _ serial nF.lmber 2072089. the 1-7/ 32" wide width rear bushing will protrude inside the block approx.imeter, 1 / 4" when installed. THIS IS NORMAL.

On engines, aerial number 2072089 and after, the two oil holes in the rear bushing must line up with the two oil holes in the block when the bushing is installed to a depth of 5/16".

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2015-49

Apply #2 Permatex to a new cup plug.

Install the flywheel on the crankshaft and torque boIta 66 to 70 ft. rbl.

Tap cup plug into engirKI block until JHug bottoms out against seat.

Valve Lifter Inspection 8t Replacement

Remove the lifters from the engine block. Numbef" the lifters and the holes that they came out of to insure proper re-assembly.

With an expandable bore gauge, meaaure the lifter bores.

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2015Âˇ50

Using a micrometer, measure ttla bore gauge setting. If the lifte, bores excH<! . 6650" diameter at any point, the engine block must be replaced.

Lubricate valve lifter stems witt! HOM #30 oil before installing lifters .

Install the lifters into the block and secure in place using the wood dowels (See Step Mike the valve lifters. If lifter stem 0.0. is less than .5605", replace the valve litters.

136\.

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2015-51

Camshaft Assembly And Installation

With a mic rometer, measure the front and rear of eac h bearing surface on -ehe cernÂˇ shaft.

Check the thickn8Sll of the thrust washer. If thickness is tess than .147", replece the thrust washer.

Each bearing surface must be measured in four places. Measure front and rear bearing surfaces again, 90 0 from first measurement. If the 0 .0 . of any bearing surface is less thin 1.748", the camshaft must be replaced.

Clean the camshaft thoroughly and blowout the oil holes with compressed air. Place the thrust WtlIhar on the camshaft and install the shaft key.

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2015-52

He8t the camshaft gear. using. gear and beering heater. to facilitate assembling the gear on camshaft.

Install the tab washer on the camshaft gear.

Install the retaining nut and torque 80 to 90 ft. Ibs.

Install the heeted camshaft gear on the camshaft. making sura the timing marks ara outward.

h CAUTION: Always weill asbestos . . gloves to prevent burnmg yOU! hands when handlmg heated parts

Bend the lip of the locltwasher over one of the flats on the rauining nut.

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2Q15-53

Install the camshaft part way into the engine block.

the thrust washer, all bearing surlifter earns with HOM #30 oil . .

Push camshaft all the way into the engine block and align holes In camshaft ge.r with hoi •• in thrust plate. Install external tooth Jockw.shers and botts.

Align the timing marks on the camshaft gear with the timing mark on the crankshaft.

TOrQue bolts 171:0 '20 ft. Ibl.

Place.:a dial indicator on the camshaft gaIIr and check backlash between -camshaft. gea, and crankshaft g.8r. Backlash must be .0002" to .006", If backlash exceeds .006", the gear. must be replaced. NOTE: Excess backlash could also be caused by WOrn camshaft bushings.

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2015-54

Install oil slinger ring over end of crankshaft with cupped face toward crank gear and notch aligned with key way on crankshaft.

Set timing gear cover with fuel pump on engine block aligning dowels to position cover. If equipped. install one piece timing gear cover 8t water pump housing with fuel pump. Refer to section 2035 for front pulley seal replacement.

Apply #2 Permatex on both sides of engine block from lower mounting hole. downwards.

NOTE: If a stud and nut is located at point "A", the pump must be removed to install a hex. socket capscrew inside of pump housing.

Install new timing gear cover gasket over aligning dowels. Apply #2 Permatex to open face of gasket from lower mounting hole, downwards.

Install all external bolts and torque 25 to 30 ft. Ibs. on aluminum covers and 36 to 42 ft. Ibs. on cast iron covers.

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2()l5-S5

Install the two intemal bolts and torque 25 to 30 ft. Ibs. on aluminum cove" and 36 to 42 ft. Ibs. on cast iron covers.

Install the Idler gear shaft on the engi~ block aligning the open end of the oil slot in the idler gear shaft with the opening In the circumference of the seat in the engine block.

Cut off protruding gasket flush with housing. With a bore gauge. measure the 1.0. of the id· Ier gear bushing .

STEP 202 , -:,' Y.

··-.,\i '

-,~2:'

Measure the 0 .0 . of the idler gear shaft with a micrometer. If 0 .0 . is leu than 1.3740", replace idler gear shaft.

Measure the bote gauge dimension with a micrometer. If the 1.0 . of the gear bushing is more than 1 .377", replace the gear.

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2015·56

lnatall idlef'«geer with lerge hub .ide the engine ,block. on the idler .haft.

toward. ~ .. ,

•

:J' "

!:;~;'~='~n~u:m~be:'r~O~f~':aflimS Ie,

clearance

-'{'"

' ~

to maintai a thrust plate end ·.d- . .f (

I>lil~' •

, ~

....

Install thrUsf:,p1ate next.

W$ ..etMline on top dead canter with nu:;~~ one~~lndet: ·.;h to1nrresiion stroke,.

••

will IM; "-a timing 1nark-'on the camshaft lined up with idler gear pointe,. Be ;~',;:;:;:'" jection pump drive gear timing maril is aligned with other end of Idler gear pointer.

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2015·57

Torque idler geer retaining bolts 35 to 42 ft.

lb •.

Remove mounting bolt. and by mea luring the thicknen of the shims with • micrometer, add Of" deduct ahimc to obtain correct clear-

ance.

With • feeler gaug8 check the nmning clea,· ance between thrust washer and id.... gear. Tha running clearance should be .003".

Reinstall mounting bolts tn leKer gear, torque 35 to 42 ft. Ibs. Than band lock plata 0\1&1' retaining bolts.

Taka • screwdriver and hold cam g •• r to h can' t move. I~II • diel indicator to chedIi back Laah. Bectdash must not exceed .006", If beau-a" exceed• . OOS", replace the gee,...

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2015-58

Holding idler gear with a screw driver. check injection .pump drive gear back lash. Backlash must not exceed .007", If backlash exceeds .007", replace the gears.

Coat -seal 'area of front pulley with HDM#30. oil. align crankshaft key way and start pulley on crankshaft.

Install pulley retaining nut.

Draw pulley on crankshaft with pulley nut and final torque nut 125 to 135 ft. Ibs.

Inm!' angine oil pan and new gasket. Apply #2 Permatex on both sides of gasket at the front and rear portions only.

Torque retaining bolts 10 to 12 ft. Ibs. on the stamped steel oil pen. On the cast iron oil pan. torque the long rear bolts 16 to 20 ft. Ibs. and the remaining bolts, 24 to 28 ft. fbs.

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2015Âˇ59

Install a new cover plate gasket, covet plate and water tube. Torque bolts 26 to 30 ft . Ibs. on a luminum covers and 36 to 42 ft . lb â&#x20AC;˘ . on cast iron covers.

Install rocker arm assemblv. Refer to Steps 80 thru 96.

Adjust the valve tappets. Refer to Steps 109 thnl 119. Remove clothespins & wood dowels from cylinde r head.

Install water pump & water pump housing. R. fer to section 2056 . Install push rods.

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2015-60

Install i-valve cover .â&#x20AC;˘and "torque retaining 4 10 ~6 ft. 'Ibs. .: .

Install a new exhaust manifold gasket.

nu~",

â&#x20AC;˘

< <,

Instalf exhaust manifold and torque nuts 25 to '30 ft. IIis?

breather tube.

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-;-

:<~

;~. -----

2015-61

Install tachometer drille, if equipped.

Carefully tap drive into engine top of drive i, flush with ~ock .

block until

188 DIESEL ENGINE

207 DIESEL ENGINE

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â&#x20AC;¢

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Section

2035 CRANKSHAFT. MAIN BEARINGS. FLYWHEEL AND OIL SEAL REPLACEMENT 188 and 207 Diesel Engines

JICase

Mac 9.788"

PmNTtO IN U.s.A.

A Tenneco Gamoany

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TABLE OF CONTENTS Special Tool •...................... .. ..... ......................... .... ........ .. _.......................................................... 3

Front Oil 5"1 Replacement ..... .............................. ... ......................... _.............................•... 4 to 6 Rear Oil Seal Replacement .................................................................................................. 7 to 9 Crankshaft and Main Bearings ..••..•.•................ , .•. .......... ..............................•...•.......... ..... 10 to 29

Removal .. ........... ... ..... ... ....................... .. ................... ....................... .................. ........ .. 10 to 14 Main Bearing Cap Replacement ..................... ..... ...................................... ... ................. 14 to 16 Crankshaft Inspection and Installation ..... ...................................................................... 15 to 29 Flywheel ............................................................... ........................................................... 30 to 31

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL WHEN THIS YOU SEE SYMBOL. CAREFULLY READ THE MESSAGE THAT FOL· LOWS ANO BE ALERT TO TilE POSSIBILITY OF PERSONAL INJURY OR DEATH.

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2035-3

SPECIAL TOOLS

013506 REAR SEAL AUONINO TOOL

016028 SLEEVE REAR SEAL INSTAt.l.ATlON

0- TO 5- MICROMETERS

0 - TO 5- BORE GAUGES OR INSloe MICROMETERS FOOT POUND TORQUe WRENCH

DIAL INDICATOR

THERMO MOUNTER. MOOEL "C" ELECTRONIC -DESIGNS. INC. 5UI4 'N .- 62ND STREET MILWAUKEE, WIS. 53218

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",)

188 DIESEL ENGINE

207 DIESEL ENGINE

FRONT OIL SEAL REPLACEMENT

o Before the front oil seal can be replaced, the crankshaft pulleV must be removed. Remove belt from pulley.

Remove crankshaft pulley retaining nut.

Remove crankshaft pulley from crankshaft. Loosen crankshaft pulley retaining nut.

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2OJ5.5

STEP 7 (Cont'd) INSET A

40 .

C<>VE'

;0.

\ -.080"

TO .100"

ApSJ'y HDM No. 30 oil -to front 011 ... 1. Front oil $881 removed.

Apply HDM No. 30 oil to shaft of crankshaft

pulley. Inmll pulley on crankshaft . . 1.....lr. naw seal in the timing wtth the seal lip Inw.rd. to • the outer edge •• shown In In"t A or tB.

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'natall crankshaft pulley retaining nut.

Crankshaft pulley 'nstalled on engine. Connect bett to pulley.

o Torque crankshaft pulley retain'ng nut 1215 to 136 ft. Ibs.

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2035-7

REAR OIL SEAL REPLACEMENT

In order to replace the re., oil seal. the gine must be ,.moved from the m.chine.

en~

Seal carrier removed from engine.

Remove flywheel from ,ea, of engi.... -OI8nkÂˇ

.......

Apply pennetex No.2 to engina bkdt from lower bolt holea to bottom of block. F1ywheeI r..-noved from engine.

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_STEP 21 (Cent'd)

CARRIER

---L"~

BLOCK

CLOSED END SEAL UP

Install new Hal carrier gasket on engine block. Apply Permatex No. 2 from lower bolt hole, to bottom of gasket. Trim excess gaske t material.

Slide seal on "eeve tool until carrier is againat gasket on engine block. Remove sleeve tool.

Install sleeve, Case Part No. G15028 on end of crankshaft.

Install Aligning Tool. G13506 with the tool pins in aligning holes of carrier. The tool must be installed over the flange of the crankshaft.

Press new rear oil seal into the carrier with seal lip inward. until seal is flush with rear of carrier. Apply HOM No. 30 oil to rear oil seal.

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IMUlIl the top carrier mounting bolt and the two bottom mounting bolts.

Tighten Ute mounting boltl snug, until gasket and carrier i. against engine block, then remove the aligning tool.

New ...1 and _ I carrier In.ulllad on engine.

ItUbll engine fttt'Wh..1 and torque mounting botU 16 to 70 ft. Ibl.

FIywhMII installed on engine.

Install f1Imam'"g am.r mounting bofb .nd torque all bolla 12 to 16ft. lb..

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2035-10

CRANKSHAFT AND MAIN BEARINGS

Removal

Remove the engine 011 pan.

Remove the water pump.

Q Remoye the engine flywheel.

Remove the water pump housing.

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Remove the water tube.

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2035-11

Remove cover plate ftom timing gMr cover.

Remove the manifold stud nuts. washers and retaining clamps.

If equIpped, remove timing geer cover plate

with integral water tube. Remove the front of the manifold off of the front.stud . Swing manifold upward and remove the manifold from the rear stud .

Disconnect the inlet fitting. leakoff line. throt. tie control and governor control from fuel in. jection pump. Disconnect the high pressure lines from the fuel injectors. Remove crankshaft pulley.

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2035Âˇ12

Remove idler gear and snaft.

Timing gear cover removed.

Remove timing gear cover.

Remove oil .linger from end of crankshaft.

If equipped, remove the one piece timing ge., cover and water pump housing. NOTE: If 8 hex. bolt is located at point "A", the wate, pump ia not required to be removed. I! stud and

Remove the oil pump and shims from front main bearing .

nut Is located at point "Au, the water pump and the inner socket hd. bolt must be removed. 80 that the one piece cover may be removed.

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If _quipped, disconnect oil pump screen brac-

Remove main bearing cap mounting bolts.

ket from 3rd main bearing cap and remove oil pump and shims from front main bearing.

Remove main bearing caps from angina. Remove connecting rod bearing cap nuts.

lift the

Cl1ln~aft

out from the engine block.

Remove connecting rod bearing caps from connecting rods. Check to be sure that the rods and caps are numbered as to their location in the block, If not, they must be identified for reinÂˇ stallation in their same locations.

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2035-14

Remove main bearing liners from engine block.

Crankshaft removed from engine.

Main Bearing Cap Replacement

I bearing cap in block. NOTE: Lock notches must the same side of bearing.

bore diameter at indicated. inside dimension 3.066" to 3.067"

Install replacement main bearing caps and bolts. Torque bolts 90 to 100 ft. ibs.

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STEP 56

.030~

' __--,";J(,, , mOM

AEMOVAL BfA-RING CAP

','

If vertical dimension i. out of toIenince or cap I. shifted side-"",Ise, ,_arit cap by,.. moving .030" stock from ITllltin9 surface and then bore out 10 meat tolerance as specified in Step 55 . IMPORTANT: If .030" stock was required to be removed. the same amount must be machined trom tha lock groove, to prevent

lur. to machine new mounting IUrface flat. ao ttt.t c.p will set solid without wobbling in block.

interference when instaltlng liner• •

Crankshaft Inspection and Installation

Using a puller, remove crankahah gear from

crankshaft.

M ••• ure the main bearing journal. fOf' WM'. Me..ure front and rear of ••ch journal. If

diameters ara smaller than 2.8730 .... unde,lizi bearing linen (.002") must ba uled. NOTE: When joumals Ire WOrn more than .002", the cranklhaft must be ground und..· size .010''.020'' or .030". Refer to Specftication.. Sections 1026 or 1027 for grinding dimension•.

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203M6

Recheck main bearing journals 90" from the first measurements for

out-ot-roundness. If out-ot-roundne•• exceeds .0005", the journals must be reground and undersize liners u.ed.

Recheck rod journal. gOO from the first measurements for out-of-roundness. If out-of-

roundnen exceeds .0005", the journals must be refinished.

Q Measure the connecting rod journals. M•• sure front and rear of each journal. checking taper. If taper exceeds .001". the journals

Heat crankshaft gear, using 8 gear and bear· ing heater, to fseilnat. assembling g •• r on crankshaft. -

must be refinished .

•

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2035·17

Install key and heated crankshaft' gear with timing mark outward. on crankshaft.

I\.. ..

Measur. thickne.. of thrust suriace of can· ter main bearing liner. Minimum th,ic.kness of thrust surface is .1025" . Replace liner if dimension is lesa than specified.

CAUTION : Always wear asbestos gloves to prevent bUlrlln9 your h.mds when handlmg heated p.Jfts

Make sure the timing mark on crankshaft gear is outward.

bearing bore in the block and the bearing caps must be absolutely clean and free of dirt or grea.. , Any dirt left be· hind tha bearing liners will interfere with the :1 lube cooling- of the bej'ring liners and will result In "hot sPCl!ts ~ ind premature failure . .~

.'!>

o Install bearing liners in engine block. with lock of liner engaging lock groove in block.

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203S-18

Install crankshaft in engine block.

Install main bearing caps and torque cap mounting bolt. 90 to 100ft. lbâ&#x20AC;˘.

o Wipe clean the main bearing journal. and place a piece of plasti gauge on the journals.

Remove the main bearing capâ&#x20AC;˘.

main bearing caps making aure liner lock '" aligri, with lock groove in cap. U. . . sliding type movement when ' ln... lling liners. never press on center of liners.

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The flattened plastl gauge wll be found on either the bearing shall or crankshaft. Compare the flat'tenttd gauge material at It. widest point with the scale that i. furni.hed . The number within the graduation Indicate. clearance In thousandth. of an Inch. eearing oil c~rllnce .... ould be .0012H to .0042H. NOTE: Und.,.lze liners are available. If It '- necessary to grind down one or more journals, it I, adviuble to grind all the joumals.

lubricate the bearintl liners with clean HOM No. 30 011.

Install the cranksh.ft into the engine.

Utt crankshaft from the engiM.

Mike aure the timing rmlrQ on the CrllnksMft gHr and the double merttl on the camshaft g. .

e,.

.lIg~.

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o Lubrlcatll b8anhg liners and cranksllaft journals with clean HOM No. 30 oil. Install the main bearing caps in the e ngine. The numbered side of the main bearing caps must be toward the camshaft. IMPORTANT: The main bearing. are numbered from 1 thru 6. starting at the pulley and of the crankshaft. Make sure the mairt bearing caps are installed in the correct numtieted location.

Torque main bearing cap mounting bott. 90 to 100 ft . lbâ&#x20AC;˘.

o Install main bearing cap mounting bolts.

Check tho crankshaft ' end play. The crankshaft end thrust is- -taken up by the center bearing liner flange. To obtain an accurate reading. place a dial indicator on the crankshaft gear and use a pry bar between the crank throw and No.2 main bearing cap. Take up all the end play and check indicator reading. Maximum end pla.y is .015 ". If excessive end play cannot be taken up by a new center main bearing liner. the crankshaft must be replaced .

â&#x20AC;˘

()

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2035-21

'" ' In.taU bearing liners into connecting rod bearing caps. NOTE; Make lure linllr lock lI,ignl with lock groove in bearing cap. Use II

,'iding movement when installing liners: nover press on center of liner.

Wipe clean the connecting rod journals lind bearing liners. Place II piece of plasti 911uge on the connecting rod ca p liner.

Inltall thll c onnecting rod cap with corresponÂˇ ding number as connect ing rod toward the camÂˇ

shaft .ide of engine with plasti gauge on t he connecting rod. Ratain in place with mounting nuta.

When installing connecting rod bearing caps. make SUf. the number matches the number on

the connecting rod and is toward the camshaft side of the engine.

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2035-22

Torque the rF",0J'~ecting rod ting nuts 4~ 10,,50 ft. Ibs.

Lubricate .connecting bearing liners and rod jou(nals with HOM ~o. 30 oil.

"$1.

Rem~vÂˇ3E;~~P~~

Th.

either cap or crankshaft; Compare the fla~tm..~ gauge material at its .widest point with tlte,scale that is furnished. The number within thl!'. graduation indicates the clearance in thousandths of an inch. The oU. clear-

ance must be .0010" to .0040". If the clearance exceeds these limits. undersize bearing liners must be installed to provide the proper

clearance.

Torque connecting rod bearing cap mounting nuts 45 to 50 ft. Ibs.

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Install front main be.ring cap In engine block.

Inltell enough number of Ithlms on the front main · bearlng cap to lTWIintem backlash bat· ween pump ge.r .nd cqnkshaft gaa, when mounting bort. .19 torqued, or d.mage to the oil pump may result.

Install new " 0" ring seal. in oil pump and lubricate with clean HOM No. 30 oiL

In.ten oil pump In engine block. IMPORTANT: Ca,. must be taken not to cut " 0 " ring when inlUlliing pump to engine.

Torque the oil pump mounting bolts 90 to 100 ft . Ibl. IMPORTANT: A repeated check for b8C);I •• h between the pump ge.r and crank....ft gear should be taken when bolts are torqued, or d.mage to the oil pump may result.

If .qulpped, torque the auction tube brecket mounting bolts 90 to 100ft. lb •.

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2035·24

Crankshaft. connecting rods and oil pump installed.

Place a dial indicator on the camshaft gear and check backlash between camshaft gear and crankshaft gear. Backlash must be .0002" to .OOS". If backlash exceeds .006", the gears must be replaced. NOTE: Excessive backlash could also be caused by worn camshaft bushings.

o Place • dial indicator on the oil pump drive gear and check backlash between pump drive gear and crankshaft gear. Backlash must be .002" to .OOS". If backlash exceeds or is leu than specified, add or delata shims between oil pump and front main bearing cap to obtain correct backlash, See Step 93.

Install rear oil seal and seal carrier. See Steps 18 to 26.

o Install flywheel on end of crankshaft and torque mounting bolts 66 to 70 ft. Ibs.

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2035Âˇ25

Inltall 011 slingllr on crankshaft with concava side facing outward.

Install tfmlng g6ll1 cover on eng I.,. blodt.

flIulp~d. ilWUll on. pieea t imirtg gear _ coverand weter pump houling.

Appty PermatelC No. 2 to engine block fnwn bottom timing gll81 cover mounting hoW: to bottom of engine block. ..:.

Install Âˇnew timing ge.r cover ~lket on ongine block. Apply PermltelC No. 2 to g"et from bottom timing ge.r covar mounting hoi. tQ bottom of engine block.

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2035-26

Torque alul))i~um timing gear cover mounting ,.' bolts. 25 to 30 ft. Ibs.

gear 7'Shaft in· engine groove aligned with Torque cast Iron timing gear cover mounting . ~ bolts, 35 to 42 ft. Ibs.

r.~

gro0V8~in

~. 'I'''' p

...

block.

,,'

•

LARGE Hue " ' "

Cut off excess gasket maUlrial from bottom of

timing gear cover gasket.

IDLER GEAR

Install .kller ge.r on shaft ,with large hub aide toward angine block.

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2035-27

'"Itlll idler geaf mounting bortl. thrust plate,

pointei' and enough shim. to maintain I run· nlng ciHrance between thrust pt.. end idle,

Torq~

Idler gMr mcM.mting botP 35 10 42 ft.

Ib,. aend tab. of pointer to lock mounting bolU_

9"~·

With I fee'er gllUije. check the runnit19 oIN,-

With Ute engine on top dead centw and number '

one

ance

cytinder on comp,.. ..ion stroke. the id .... gee, pointer must be lined up with tim-

ing

min:

The running deill1IrM:e shoukl be .000 tf clearance i, incolTltCt. add or dellh shim. II ~ulr~ .

on the camshaft g •• r Ind timing

be~

thrust washer and Idter gea,. H

•

marfl: ' on the injection pump drive ge.r.

.-.

,..' .

,..

,""

()

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.2035-28

Install crankshaft pulley and mounting nut. Torque mounting nut 125 to 135 ft. Ibs.

..,,4

' manifold by holding .meniposition end installing to re.ar stud fir.s.t_ tLower manifold and _inStall on, ._!<> front stud~Retain with clamps and nuts. Tor- ,t que .mountiJ191"Outs 25 to 30 ft. Ibs. )lor~p.werd

If equipped. install one piece cover plate on timing gear cover. Torque mounting bolts 35 to

42ft. Ibs.

Connect inlet fitting. leakoff line. throttle control and governor control to fuel injection pump.

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2035-29

\,.:

Install water pump housing outer mounting bolts and torque 35 to 42 ft. Ibs.

Apply No. 2 Pennate" on both sides of new oil pan gasket at the front and rear portion, only.

-';~ >-:

IMPORTANT: Apply loctite Primer''T'' and Loctite#271 (Case B17429 and 817423) on water pump housing inner socket hd.cap.crew thread. to prevent capscrew backing out into impeller. Install capscrew and torque 35 to 42 -ft . Ibs.

Install oil pan and gasket. Torque st8mped steel oil pan mounting bolts 10 to 12ft. lb â&#x20AC;˘.

LONG MOUNTING BOLTS TOROUE 15 TO 20 FT. LBS .

TORQUe 24 TO 28 FT. LBS .

Install the water pump and gasket. Torque the pump mounting nuts 25 to 30 ft . Ibs.

tt equipped with cast iron oil pan, install long bolts to the rear of the engine and torQue 15

to 20 ft . Ibs. Torque remaining mounting bolts 24 to 28 ft . Ibs.

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•

2035-30

FLYWHEEL

Remove fJywheel from end of crankahatt.

Using a drift, drive ring ge.r off flywheel.

FLYWHEEL

REMOVE SPECIAL OUTPUT HUB If EQUIPPED

STEP 124 • OIL SEAl

\ ""'@,

BEARING

'Preheat new flywheel ring gea, 4000 .10 4500 F. in oil or in an oven. 00 not us•• torch to heat ring gear. Install ring gear with chamfer side of gear teeth outward and larger 1.0. chamfer toward flywheel.

1'}. .. SNAP RING

CAUTION: Alw .. ys

we,.,

"sb/!~Io~

gloves [0 p"'vf),,1 hll'''''''} YUllr h,j"d~ wh"n h,md{Iflfl }"'.Iied p.,,15

If equipped with 8 dry clutch tractor flywheel. disassemble flywheel componentl.

1.0 . CHAMfER

TOOTH C'''''FI''

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Ring geer installed on flywheel .

Install flywheel on end of engine c rankshaft. Torque flywheel mounting bahs 66 to 70 ft.lb, .

STEP 128 STEP 130 TORQUE 65 TO 10 FT. LSS . BEARING OIL SEAL

SNAP RING

On dry clutch tractor flywheel , install snap ring in groove of flywheel. Pre.. bearing in until seated against snap ring from the gear side ot flywheel . Install new all seal from rear side until seated against the snap ring . Inmll new " O "·ring. lubricate oil ...1 and "0" ring with drive·away oil.

188 DIESEL ENGINE

OllTPUT HUB

On hydro~.tic tractors, lubricate the spline hole and face of hub liberally whh No.2 Moly Diaulfide grease. Install flywheel and output hub. Torque retaining boh. 65 to 70 ft . lb •.

207 DIESEL ENGINE

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Section 2045 OIL PUMP 188 and 207 Diesel Engines

J I Case

R ae. 9 -78885

I'!t1t<TEO IN U.aA

A Tenneco Company

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_2045-2

TABLE OF CONTENTS SPECIAL TOOLS

.................................................•.............................. , ................................ 2

Oil PUMP

Oil Pump Removal ..................................•......... .... ~ .............................................••.•....... : ..... 3-5

C < Od Pump InspeCllon ........................... ............ .....•. ...•.•................................•....................... 5 · 1 0 Oil Pump Installation ............... ............. ...... f~

....... -j.J.

~. =

. . . . . . . . . . . . . . . . . . . . ..

11-14

. , .,

SPECIAL TOOLS

SPRING TESTER

OIAL INOICATOR

FOOT POUND TORQUE WRENCH

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OIL PUMP

188 DIESEL ENGINE

207 DIESEL ENGINE

Oil Pump Removal

Remo""- 00 pan drain plug and drain oil from engine. Remove oil pan mounting bolt..

Oil PII"

remo~

from engine.

Re move Gil pan and gasket from engine.

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Remove

cJi

pump mounting bolts. C

Remove oil

from engine.

If *lu;pPÂŤl~ IooMn oil pump 'tUbe bracket bolts from maIn bNring -cap _nd then remove oil pump mounting bolts.

.-...

Remo~ 'suction

... -".

<tUb. from 011 ;'"

.:~,

pump.

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2045-5

Remove shims from top of front main bearing.

Engine oil pump removed .

Oil Pump Inspection

'CR,\' . COVER MOUNTING

PUMP COVER

)

~" o o.

/0 .

COVER GASKET

CUP PLUG

O·

COVER MO UNTING BOLT (41

VA'V' .""NG

c;<

~RELIEF

"0" RING _ _ • •_. ___ ~

,, GEAR

VA LVE

COTTER PIN

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2045-0 STEP 9

Remove pump cover mounting bolts.

:.rw.

o Remow pump cover mounting scrawl.

Using a foeler gauge, check pump drive gear

to pump body clearance. If clearance exceeds .010 inch, the pump must be replaced.

Remove pump cover and gasket from pump body.

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2045-7

", '

Using

feeler gauge, check PtJmp gears to

body radial clearance. If clearance is greater than .008 inch. the pump must be replaced.

Torque pump cover mounting bolts 6 to 8 ft. Ibs.

Remova pump cover from pump body. Place II piece of pl88ti gauge on one Of!f18

pump ge.rs.

Measure pump

Inatan pump cover and gasket on pump body.

plam - gauge

cover

ceeds .008 placed.

obtain

cleal1lnce. If inch, the ptlmp

gear-to-

cle.rance must

IIlIt-

re-

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2045-8

o Install new pump cover gasket on pump body_

Install pump cover mounting bolts.

o Install pump cover on pump body:

Torque pump cover mounting bolts 6 to 8 ft. Ibs. NOTE: While tightening bolts and screws. position the cover to provide free rotation of shaft and gears.

Install pump cover mounting screws.

" Remove .cotter pin retaining relief valve and spring.

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STEP 28

Remove cup plug from body.

Check relief _tva spring for the foUowing: Free ..ngth ................. ........ ........ .... 2 .126"

Load et 1 .44 H

. . . . . . . . . . . . . . . . . .. ...

18 to 19 lba.

Remove relief vatve spring from body.

Install relief valve in body with cloaed end toward pump.

Remove relief valve from body.

Install relief valve spring In body.

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2M~lO

â&#x20AC;˘

STEP 33

InataU cup plug in bod.,. with closed end outw.rd.

Bend cotter pin to retain -in place.

Compress relief valve spring and cup plug until plug ia below cotter pin hole. Insert new cotter pin through hole in body.

Engine oil pump ....embled.

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•

204>-11

Oil Pump Installation

o Install shims stall a \Ihlm thiclmen so g ••.~'." not

on top of front _main bearing.lnpack with a minimum of .016", -that pump gear and crankshaft jammed togethe,. Rafar to Step

Lubricate " 0 " ring seal with clean engine oil .

-o -,

o Install suction tube on oil pump. 'Torque suction tube nut 96 to 105ft. lb •.

i ' on top of shims and front Use care not to cut "o-ring on sharp edge of block duro ing pump installation .

o ..,.1

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in pump body.

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â&#x20AC;˘

()

Install oil pump mounting bolts. -

Oil pump installed.

o Torque oil pump mounting boltl 90

Ibs.

~ 100 ft.

Oil ' pump with ' suction tube bl1lcket installÂˇ ed.

.,,">

If .qulpp.d, torque pump mounting boltl and suction tube bracket mounting bolts 90 to 100 ft. IN_

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•

Place a dial indicator on the -oil pump drive gear and check backlash between drive gMr and cranksttaft gear. Backlaah mu~ be .002 to .008 inch. If backlash exceeds or i, unde, the above range, add or delate shima between oil pump and No.1 main bearing cap to ob· tain COMet backlash. S_ Stap 315. NOTE: Oil pump shima are .002 and .006 inch thick.

Torque stamped stee4 bolta 10 to 12 ft. Ibs.

oil

pan

mounting

Apply No.2 Permate" on both sides of new oil pan ga.et at the front and rNlr portions

onty.

•

TORQUE 15 TO 20 FT. LBS. TORQUE 24 TO 28 fT.

L8S.~

If equipped with cast ifOn oil pan. install long batt. to the rear of the engine and torque 16 to 20 -ft. lba. Torque remaining mounting bott. 24 to 28 ft. lha. NOlE: Torque drain plug 29 to 31 ft. Ibs. Refill crankcase with proper amount and type of oil. Refer to Operator's Manual.

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2045-14

188 DIESEl ENGINE

207 DIESEL ENGINE

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Section

2050 STALL CHECKS. ENGINE REMOVAL AND INSTALLATION. AND RADIATOR

J I Case

A TenneCo COffi;Jany

C. E. Div. 9-66015 . ._

u.s. ...

February 1976

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2050-2

STALL CHECKS During tbese tests engine stall speed will be recorded at full throttle with the engino working agains t the torque converter and/or the hydraulic system on machines

with a power Shuttle or against the hydraulIc system only on machines equipped wIth a mechanIcal shuttle.

Test Specifications Power shuttle Idle speed, , . . . . . . . . . . . . , • . . . . . Maximum no load speed . . . . . . • . . , .. HydraUlic stall speed . . . . . . • . . . • . • Converter stall speed . . . .••••... Combined converter and hydraulic stall speed

700-750 rpm (r/min) 2230-2270 rpm (r/min) 2100 rpm (r/min) 1890 rpm (4/min)

Temperature gauge needle

Hydraulic aU temperature . . . . • . .

In middle of green zone 125_1754 F

(51_79° C) Before performing the stall checks on a power shuttle machine, check to he sure the parking brake will hold the machir.e with the engine running at full throttle and th·~ transmission in fourth (4th) gear. If

WARNING:

. . . the machine moves. adjust or repai!"" thl' brakcs IlS required to hold lilt' machine. or park the machine 3gainst an Immovable object such as a wall. po!'.t or another piece of he3.vy equip-

ment.

:Hl_~l

ConverterlTransmission Oil 1.

Apply parking brake and start engine.

Shift transmission to fourth (4th) gear and place poweT'"shuttte1ever In f ol'Wll'"d. Accelerate to full throttle and hold for 15 seconds then ShUt to Neutral and run at full throttle for 15 seconds . Repeat step 2 until needle on transmission oil temperature gauge Is In middle

NA NA 125_175° F (51-79° C)

control lever to Neutral for 30 seconds. Repeat cycle until oU Is at specified temperature. If a thermometer Is not avaHable. the inlet tube to the loader control valve w1ll be very warm to the touch at the specffied temperature.

Test 1 ~ Combined Converter and Hydraulic Stall 1.

Apply puking brake and start engine. Shift transmission to fourth (4th) gear and power Shuttle to Forward,

Increase engine speed to half throttle and roll the bucket back. Hold control le ver in power position and accelerate I'D wide open throttle. The engine must continue tD run_

Oil Heating Procedure

700-750 rpm (r/mln ) 2230-2270 rpm (r/min) 2050 rpm (r/min)

Engine must continue to run NA

Converter/tran15miS81on aU temperature . . . . . . • . . • .

Mechanical shuttle

Test Summary 1.

U engine speed Is below the specified rpm or qu1ts 1t may be due to:

A worn or damaged engine, or worn or damaged I.njeotion pump, or im-

of green zone on gauge.

proper adjustments,

Hydraulic Oil b.

RUn engine at full throttle, hold control

lever In Rollback for 15 seconds then return

Excessive hydraulic system pres_ I5Ure or damaged or worn parts In the power shuttle or converter.

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2050-3 2.

If engine speed is above 1200 rpm (r/ min) it indicates inefficiency in the con-

verter, power shuttle or hydraulic system. Possible causes are: 9..

Internal leakage in the power shuttle.

Worn charging or hydraulic pump.

Low main reUef valve setting.

To Identify the problem area, conduct Tests 2 and 3, If both tests are unsatisfactory, the cause of trouble is very likely the engine. Refer to Section 2001 Engine Diagnosis and Section 2002 Engine Tune-Up.

If engine speed Is 200-300 rpm (r/ min) below the specified speed the engine Is at fault. Refer to Section 2001 Engine Diagnosis and Sectlon 2002 Engine Tune-Up.

If engine speed is above. the specified rpm (r/min) the problem is in the converter or power shuttle .

Refer to Section 60 12forpower shutUe trouble shooting information.

A tinny sound from the converter indicates damaged converter blading and replacement of the converter.

Te.t 3 - Hydraulic Stal Test 2 - Converter Stall 1.

Apply parking brake and start engine.

Sbltt transmission to fourth. (4th) gear

and place power shuttle In Forward. Accelerate to wide open throttle and record engine !speed.

Start engine and run at half throttle.

Roll the bucket back and hold control lever in power position. Accelerate to full throtUe and re<::ord engine speed.

Test Summary

Test Summary 1. 1.

excessive pressure or restriction in the hydraulic system. Check main relief valve setting as instructed in Section 4002, and possible restriction between the" 'hydraulic pump and loader control valve inlet. Repeat test; If engine speed is s till low, the engine is likely at fault.

If ,engine speed Is below the specified rpm, the problem Is In the engine or

converter.

If engine speed Is 600":700 rpm (r/ min) below the specified speed, the problem Is the one ' way olutch in the converter. To correct the prob-

lem, replace the converter.

If engine speed is below the specified rpm (r/ min) it indicates engine v.oear or

If engine speed is &8 specified the converter and power shuttle are working properly; proceed to Test 3.

If engine speed is above the specified rpm the hydraullc system Is at fault. Refer to Section 4002 for trouble shooting and hydraulic system test information.

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2050-4

ENGINE REMOVAL This procedure Is WT Itten to cover machines equipped with a power shuttle or a mechanical shuttle. The power or mechanical shuttle remains in the machine when the engine is removed.

Remove engine side panels Hao equipped and hood and muffler. Disconnectbattery ground cable at battery.

TbrotUe rod and fuel shutoff cable at fuel injection pump. Loosen cable clamp on the block and place cable out of way.

Wire from oil pressure sender.

13. DiBconnect or remove from right side of engine:

Remove radiator grille and drain cooling system.

Battery cable from starter mounting bolt. If equipped with power shuttle, remove fill tube bracket.

Disconnect tubes to power shuttle aU cooler at hose connections. Catch oil from cooler in a drain pan.

Battery cable and wiring from starter solenoid.

Hoses at power steering pump.

Wiring from alternator, air cleaner restrictIon switch, engine temperature sender. circuit breaker, and hom if so equipped. Remove wiring harness clamp and place harness out of way.

Tacrometer cable.

Tube to ether injector Usa equipped.

Remove the lower guard or if equipped with a coWlterweight, remove plate behind counterweight.

Remove the upper and lower radiator hoses.

Remove bottom radiator support to frame nuts, washers and bolts.

Remove rear mounting bolt on each side of radiator shroud.

Remove air in take tube if so equipped.

Attach chain hoist to shroud. Moveshroud forward to clear the fan blades and lift the radiator/shroud assembly from the machine.

10. Close shutoff valve on bottom of fuel tank,

11. Remove air cleaner and mounting bracket

as an assembly. 12. Disconnect or remove from left side of engine:

Return fuel line from rear fuel inJector and fuel supply Une at fuel filter.

14. Disconnect outlet hose from hydraulic pump. Install plug in bose and cap pu.m p fitting. 15. Loosen a hose clamp on each lower suction tube hose. Remove the pump mounting cap screws. Pull pump forward to disengage drive coupling and pivot pump forward. 16.

Remove flywheel bousing to engine mounting bolts and nuts, and cover on front of flywheel hOUSing. The washers are hardened. If a washer is to be replaced it must be replaced with the part listed in the parts catalog.

17, If equipped with a mechanical shuttle place a jack under rear of shutue for support.

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2050-6 18. Remove front engine mounting bolt. 19. Attach lifting sling to engine and chain hoist to sling.

20. Remove engine from machineCbeckingto make sure all wires, tubes, etc, are disconnected.

ENGINE INSTALLATION The engine is installed in the reverse order of removal. If the torque converter was removed, it MUST be centered on the flywheel witbln.004"

(0.102 mm) when it Is reinstalled or a new converter is installed. Place dial Indicator against converter hub to check for proper installation. Before installing the starter on the engine (or before installing engine) disassemble the starter and inspect the brushes, starter drive, bearIngs, etc. and repair as required.

Also saturate the lubrication Wicks with 10 weight engine oil. Refer to Section 8006 foT starter information. Refer to the various sections in this manual to make sure connections are correct. When the engine has been installed, service all filters and install coolant and engine oil as specified in Section 1050. H antifreeze Is not used in the cooling system, be sure to add a rust inhibitor and water pump lubricant Anticavitation inhibitor (part no. 331-508) must be added to all cooling systems.

INSTALLATION OF FRONT ENGINE MOUNT/HYDRAULIC PUMP MOUNTING BRACKET Whenever a new engine or engine mount is installed, the engine mountmustbeproperIy installed so the hydraulic pump and pump drIve coupling will be properly aligned.

Secure engine mount to engine with bolts, lock washers and nuts.

Wipe off pump pUot bore inengine mount. Remove pump drive coupling from cranksbaftpulley. Attach dial IncUcator topulley using a 7/1S" - NC x 3/4" cap screw as illustrated in Figure 2. Attach dial indicator to adapter 60 its stem is touch-

Special tools required to properly Install the engine mount are (1) a dial indicator capable of indicating .100" (2.5 mm), (2) the Indicator adapter illustrated in Figure I, (3) a No. :i taper. straight fluted reamer and (4) a 1/4" drill bit and electric drill.

Inc" the pump pUot bore.

Set dial indicator at zero with ample stem movement in both directions. Turn engine over and take reading every 90" until ODe complete revolution is made. Record each reading.

If the readings varied .005" (0.127 m.m) or less in either Olrectlon from zero the

MAKE BASE ,Mil 1/8" ( 3 "",I STJtI,.P

IRON OR OTHER SijITABl[ MATERIAL

r,.

/ - 1 - 1 / 4 "- 1 I (32 m i I

DRILL -oocr

7/15" (12 1TII11

5/16" X 3" ( .9 DID x 7.6_1

~f ':'

-$\ 1

(25 "'" )

3/8" _

( 9. S ml

.00

engine mount is properly positioned Proceed to step 6.

1/2'

I"j

If the readings varied. 006" (0.15 mm) or more in either direction from zero the engine mount must be repOSitioned.

After the engine mount 15 properly positioned, drlll a 1/4" hole all the way through engine block flange at the pilot boles in the engine mount,

J-

NOTa: PLACE HOD /I,IIOUT lie" (3 _1 rROH

EACH S!DÂŁ .\110 WELD IN PLAtt

1S1591

F igura 1 - DIal lndJcator Adapter

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2050-6

1 ,

:0; /,

II, \\,

\~ \ \

\ \

@ 0

I' 1'1

\\,:0:

\\'

\\\

,I, I

I I

\" "

, ", ,,"

- - - ----------

....

, //~// /1

_.... .,'"/ ' " , /

....

" .... ....

I" , II

•

-------

.... ., ..... /

•

I. DIAL IMDICATOR ADAPTER Z. DIAL INOlCAIOR 3. CRANKSHAFT PUlLEY

MIN( ItOOMT

OOoIEL PilI. HOLE

F igure 2 - Engine Mount Ins tallation

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2050-7

â&#x20AC;˘

NOTa: If a new engine mount is being mstalled on a used engine or a used engine mount is being used on a new engine, drill the 1/4" holes 1/2" above the engine mount pilot boles.

\.,- 1

Using the No. 5 tapered str8..lght fluted reamer. ream the 1/4" boles to fit a No.5 x 1-1/2" pin (part no. 139-64), The fit must be snug enough so the pin must be driven into place with a hammer.

Drive new pins into place.

RADIATOR REMOVAL AND INSTALLATION 1.

shroud from machine. Set shroud on

Remove grille and drain radiator.

blocks.

2. 3.

Remove lower guard (or cover plate if equipped with a counterweight).

'-..)

Remove nuts and lock washers from studa on bottom of radiator.

Disconnect oil cooler lines at bose con_

nections. Plug oil cooler to prevent oil loss and keep machine clean. Plug cooling lines to prevent entry of dirt.

10. Remove the radiator mounting strap to shroud nuts, washers and bolts on each stde. '!ben remove radIator from Shroud.

Remove bottom radiator support to frame nuts, washers and bolts.

11. U radiator is being sent to a repair shop, use a sharp putty knHe and remove the foam rubber baffles from the radiator, Also remove the 011 oooler.

Remove the upper and lower radiator

12. Radiator installation is the reverse of removal.

hoses. 6.

Remove all' cleaner intake tube if so equipped.

Remove the rear llKJUllUng bolt on side of shroud.

Attach cham hoist to Sbroud. Move ShroUd forward to clear the fan blades and lift

13. Use

Ii. good grade of contact cement according to the manufacturer's lnstructlons and cement baffles to radiator. The baffles must not be left off.

14,

[f permanent antifreeze is not used in the cooling system be sure to use a rust icb.ibitor and water pump lubricant. Also add anticavitation inhibitor, part nuznber 331-508.

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2050-8

•

......

...

-.a

•

, '"

:ell

.,.. ,. "'" . oi.

....

;.,-~

•

--~.

• • ••, 1Slst)

Figure 3 - Radiator and 011 Cooler Installation

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•

Section 2051 AIR CLEANER

AND SPARK ARRESTING MUFFLER '.

J I Case

A Tenneco Company

C. E. Div. 9-66015 ""mbl

IN U.f .....

February 1976

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2051-2

.}:

•

a 1. Z.

BAFFLE OUST CUP

SAFETY FILTER

FilTER RESTRICTION LIGHT SWITCH

FILTER BOOY

15!6l1

INTAKE TUBE

Figure 1 - Air Cleaner Installation

., ..

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2051-3 "

AIR CLEANER SERVICE Service Interval The air cleaner filter element mlSt be serviced when the filter restriction warning light remains 00 with engine running at full throWe. 10 addItion to filter service the dust cup sbould be cleaned dally or more often as conditions warrant.

lng. U metal covering Is dented or bent. inspeot !titer paper (or 'holes OJ;' rub spots in that area. If holes or rub spots are noted, discard the nIter and install a new filter

element.

Filter Element Service Washing Is the preferred method of c leaning 1he element as it removes more dust and soot. thUB restoring the element to an almost new condition.

Wash the fUter in Case Filter Element Cleaner. Part No. A4091O. Mix acCOrding to instructions on container. Do not use water pressure over 40 psi (275 kPa) at the nozzle. Let the element dry completely before installing. Do not use compressed air to dry

101111

the element.

-- -~-

rl ..,

Use of compressed air to clean the element Is permissible but not recommended as

Figure 2 - Inspe¢ting the ElemSlt

it does not remove carbon and soot. Whenusing compressed all'. use no more than 30 psi (206 kPa) at the nozzle and keep the nozzle a reasonable d istance (no c loser than 1" (25 nun) away from the filter . Y.ove the nozzle up and down each pleat, blowing from the inside only. Inspect the filter after ltis cleananddry. Place a l1gbt ins ide the filter and inspect for holes, teus, and dented or bent metal cover-

NOT.: Inspect new CUter e le ment In the same manner, Do not accept a defective

filter. The element must be replaced after It has been cleaned six times or once a year,

whIchever occurs first.

"' "J

•••

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2051-4

SAFETY FILTER (FILTERED FITTING) The filtered fitting Is installed in the air intake manifold, Figure 1. The fllterprevents unfiltered air from entering the engine if the filter restriction light switch Is damaged. The safety filter will plug up with conUnued operation if a leak occurs. If the filter becomes plugged the switch will fall to operate.

Place the shuttle and transmission in Neutral and apply the parking brake.

•

Start the engine. Block off the intake tube. If the fUter restriction warning light on the instrument panel does not light, the fUter is plugged or warning light switch is inoperative. Remove the fitting from the manifold Soak fitting in cleaning solvent and blow

moisture free compressed air through the filter.

Checking for Plugged Safety Filter 1.

•

Refer to Figure 1. Expose the filter body intake tube.

Install fitting and switch and repeat step 3. If filter Is still plugged, replace the fitting.

FILTER RESTRICTION LIGHT SWITCH The filter restriction light switch can be checked for proper operation using a manometer (Usually found on ignition distributor tester) and an Ohmmeter. To check the switch, connect an Ohmmeter lead to the switch terminal and the other obm-

meter lead to the switch body. Connect hose from manometer to the switch and slowly increase the vacuum The ohmmeter should show continuity (switch closed) at 2.2 ± .3 inches of mercury (7 ± I kPa). If the switch does not function as spectfied the switch must be replaced.

SPARK ARRESTING MUFFLER Laws of some states or provinces may

Remove plug from side of muffler. This is a brass plug; if it requires replacement It MUST be replaced with another brass plug.

Have a second person available to block the outlet pipe .

require that this machine be equipped with

a spark arrester or spark arresting muffler. If machine is equipped v.r1th a spark arresting muffler, a pipe plug w111 be found on the side of the mu.ffl.er, Figure 3. If the machine Is equipped with a spark arresting muffler, any replacement muffler must also be of the spark arresting type .

Pull fuel shutoff control out.

The spark arresting muffler must be cleaned (loose carbon removed) after every 100 hours of operation.

Apply parking brake. Turn switch on and crank engine for 30 seconds while helper blocks the ouUet pipe.

Reinstall plug in muffler.

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2051-6

t 3

•

l. 2. J.

AMPT£R (US£U IIlTItOUT ItOIS[ CO:mtOl.I ADAPTEIl (USfD !lI1H K01SE COKTIIOl)

STANDARD

4. 5.

SPAlll AAAESTIIIG I'IJffUR aruSION (US£tl WIlli 80TH lIJifUU)

~Fl[R

1~ I Rl

Figure 3 - Muffler installation

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Section

2053 "

ETHER INJECTION

J I Case

C, E. Div. 9-6601 5

A Teolleco ComP4l'Y

February 1976

"1NfIO IN

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2053-2 ,. -~

1r--::::l-<YLlNOER

Operation The ether injection system injects a measured amount of ether into the intake manifold whenever the control knob 15 pulled all the way out and pushed back in. Actuate the ether injector as the engine is being turned over with the starter. If the engine starts but fails to continue to run, actuate the injector again as instructed. DO NOT actuate the ether injector with the engine running. ~. ,.

I-':

1lI1lO001lll

"'"' -+~

,"""

When the control cable Is pushed all the way in. there should be 1/8" (3 mm) clearance between the knob and the cable hOUSing end.

Figure 1

Cylinder Replacement 1.

Be sure control cable is pushed all the way in.

Loosen cylinder mounting clamp and unscrew cylinder. Dtscardcylinder according to 'instructions on the cylinder.

H O-ring remained in injector valve, remove a-ring and discard.

Install new cylinder using a new a-ring.

To adjust control knob position: 1.

Loosen cable clamp at injector valve.

Hold injector valve lever down and push cable housing up and tighten clamp.

, f

Check control knob pOSition and readjust as required,

I liS ' (3 m)

CONTROL

Control Cable Adjustment

.......

()

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2063-3

,.q1

â&#x20AC;¢

Figure 2 - Ether Injector Installation

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~-'..

Section 2055 ..

COOLING SYSTEM

188 and 207 Diesel Engines , Thermostat and Water Pump

()

. - --

.. .

.. , .

, -'

. .' .

;

'" ..'

o http://stores.ebay.com/UsefulCDs J I Case

Rae 9 -788115

PAIr.rTED IN U.s.A..

A Tenneco Company

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.- -

2055·2

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL WHEN YOU SEE THIS SYMBOL CAREFULLY READ THE MESSAGE THAT FOL· LOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.

SAFETY PRECAUTIONS , CAUTION Add coolant to the radIator only when the engine is stopped Of Ll. slowly idling_ To avoid being scalded ~ when the pressure-type filler cap is being removed, tum the cap slowlV to the first stop position to relieve pressure before removing the cap,

•

10-radJllitor ReT-leO ;~~ s'y~am pressure by tuming the cap counter-clockwise to the FIRST s.toJ. ::rbis, will allow a gradual reduction in @fessure and minimize coolant loss . .W' ~ ~:. NEVER pour cold coolant into a hot engine. The engine block or the cylinder head may crack by the sudden contraction caused by V(fi:e . ~ff~ce -,II}. .t emperature between the metal and the coojant.

..tl-:)!_~

(2-~"{."

;"\<.:.;J.-'

CLEANING THE COOLING SYSTEM It is recommended that the cooling s~e:m bt cleaned at least once a year. In areas where water containing scale forming minerals is all that is available. clean the system more often.

_~\r.'

i.v~...

t~rer~

Follow", tha directions provided with ., ,,~1; I ~

ltie~leaner;/ F

3. After draining the cleaning solution. flush theaystem with clean water before refilling for operation.

1. While the coolant is still hot, open the radiator drain valve and the engine block drain valve.

NOTE: Always use only a -nationaUy recog-

2. Add any-nationally known commercial brand cleaner marketed by a reputablemanufac·

nized brand of High Boiling Point Ethylene base anti-freeze, that does not contain a stopleak additive.

188 DIESEL ENGINE

207 DIESEL ENGINE

'.'-

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THERMOSTAT REPLACEMENT

Removal

DiKonnect and remove hOM from thermostat

Remove an old "uk.t material from mounting

housing. Remove thennost.t hou.rng bolts.

luri8eeâ&#x20AC;˘.

Inspection STEP 5

Remove thermostat housing and gasket.

Cheell thermostat f~ propef operadon by IUb-merging in a container of hot (approximately ,760 F) wat.,. The thermostat Utould be completely open tilt If it

2020F. Replace the thermo.-

doe. not meet the above s pecification.

Uft thermostat out of water pump hou8ing

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'., 2055-4

Installation

Install thermostat in water pump housing makÂˇ ing aure thllt the thermostat point. upward and toward the radtetor.

Install thermostat housing.

o Innall thermo.tIIt housing taining bolt. 36 to 42 ft. Ibs.

. Torque , ..

InsUlIi new thermostat housing gasket.

o http://stores.ebay.com/UsefulCDs Thermostat housing installed. Install radiator hose to thermostat housing.

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2055-5

WATER PUMP REPLACEMENT Removal

u:.~

Remove feo blade.

Remo ve water pump mounting nut • .

•• Remoye fan nub-apacer, if equipped .

R.move wlter pump and gasket.

Remove fan drive pulley.

Flamove inner mounting bolt.

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o Remove water pump housing and from cylinder head. Check housing for cracks at mounting flanges and replace if necessary. NOTE: If equipped with a one piece water pump and timing gear housing and replacement is required. you will receive a separate water pump housing and timing gear housing. refer to Section 2016. SEPARATE WATER PUMP HOUSING AND TIMING GEAR HOUSING

o Remove water Pump housing bolts.-Â· ONE PIECE WATER PUMP AND TIMING GEAR HOUSING

Water pump housing and gasket removed from cylinder head.

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2055-7

Installation

Remove 1111 old galket matlrle' from mounting

Install outer bolts. and torque 36 to 42 ft. lba.

sutfece. IMtall II new wet. pump OO"'n" to cyRnder Mad gll.bt.

lnltall II flew "0" ring. tI.lng lubriplete.

1nn.l1 water pump houaing to _ter tube lind

timing gear houling.

IMPORTANT: Apply Loctlte Primeru T" and Loctlte #271 (ea.. 817429 and 817423)'on wate, pump hOU8lng inner socket hd.capSCf8W threads to prevent capscrew backing out into Impeller. Install capacrew lind torque 35 to 42 ft . lb â&#x20AC;˘ .

Inspect water pump housing to-water tube hOM for creeks lind deterioration . Replace tf nee.nary. Install h016 on water pump housing lind on water tube. Secure with CiampI.

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2«;5-8

Remow ell old gaPItt materia' from mounting surface.

1nn.1I fIIn drive pulley.

Install a new pump to hou.no gasket.

Q. Install fan hub apecer, if equipped. Install water pump on pump housing stud•. NOTE: 1M Wllte, pump is serviced . . . unit. If pump is leaking or malfunctioning. replace the

untt.

Check fIIn for damage 01' loose blad... Replace fan if required. In~1I fan on pulley and apacer. if required, and r torque retaining bolt. 17 "'to 21 -ft. lb•. I~II

nut. and torque 35 to 42 ft. Ibs. NO'l'E: no.. J r c- c-.,...,. ......... tt.. In ...... .. changes

I..

~ .. tlorto

.....,

rilh! ,"".

Mm....

Imprew_

..,IIM",

Inc"rring "...,

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Section

2125 CYLINDER BLOCK. SLEEVES. PISTONS AND RODS 207 Diesel Engines

J I Case

R.,,_ 9 Â·78845

~ I ""'ro

u.s A

ATennecoCompany

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2125Â·' TABLE OF CONTENTS Special Tools .... ..... .......... .................. ............. .... ...... .......... " .. ........... ... ......................... ........... ... 3

CYLINDER BLOCK. SLEEVES, PISTONS AND RODS ... ..................... ..... .... ... ................... 4 to 19 Removal .... ........................................................................................ ............................... 4 to 6 Cylinder Sleeve In$peclion .. ............ ..... ..... ... ...................... ..... ..... .. .. .. ............................. . 7 to 9

Cylinder Sleeve Rem oval and Installation .. .... ... ............ ................. .. ... ................ ... .......... 9 to " Piston and Connecting Rod Inspection and Installation .................. .. .. ... ... ..................... 1 1 to 19

SAFETY THIS ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SFF THIS SYMBOL CAREFUllY READ THE MES.SAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.

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2125-3

SPECIAL TOOLS

0" TO

IS ~

MICROMETER

FOOT POUND TORQUE WRENCH

OH TO

BORE GAUGE

OR INSIDE MICROMETER

DEPTH MICROMETEfI

DIAL INDICATOR

TOOLS FOR CHECKING SLEEVE PROTRUSION A40682 CLAMPING BAR

\ TO MODIFY M0681 CLAMPING DISC TO ACCOMMODATE 207 OIESEL ENGINES

e I

CUT ON OUTER DIAMETER OF GROOVE

TO DIMENSION SHOWN

4 .280

()

b-----------~----------1 A28312 BAll

A142802 CLAMPING OISC

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2125-4

207 DIESEL ENGINE

CYLINDER BLOCK. SLEEVES. PISTONS AND RODS Removal

Remove the cylinder head and manifolds from the engine block. Refer to section 2015 for removal.

Remove drain plug from oil pan and drain engine crankca58 oiL Remove oil pan .

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2125-5

STEP 5

Check the connecting rod side clearance with a feeler gauge. If side cleerance exceeds .0"", the connecting rod must be replaced.

Check the piston sleevas for a carbon or a matal ridge at the top of the ring travel. If a ridge is present, it must be removed before the pistons can be removed. Use a plastic scraper to remove carbon ridges using the top of the piston as II guide for scraping.

Check the connecting rods and caps to see if they are numbered as to their location in the engine block. If not. they must be numbered for reinstallation in their original location on the camshaft side of the engine.

Remove the connecting rod cap mounting nuts.

IMPORTANT The piston "Ieeves are chrome plated. Sharp instruments must not be used to remove carbon from piston sleeves because there is a possibility of scratching through the chrome surface and eKposing the iron. which in tum will have a tendency 10 rust. Never usa a ridge reamer to remove 8 ridge due to metal build-up. If a metal ridge has formed. replace the piston sleeve or damage to the piston rings and lands will result.

Remove the connecting rod caps.

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2125-6

Push the connecting rod up through the en. gine block.

Remove the pistons and rods from the cylinder bloet. Reinstall rod caps On corresponding conrleCting rods to avoid mixing of the caps.

Remove piston pin retaining rings from piston.

Remove piston pin from Connecting rod and piston.

To avoid damage to the pistons and rings. use II

ring expander and remove piston rings from

piston.

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2125-1

Cylinder Sleeve Inspection ST.EP 13 Inspect the cylinder sleeves for the following conditions.

NORMAL WEAR

A amooth shiny surface along the complete length of the cylinder sleeve indicates a wom out sleeva due to nonnal wear and it should be replaced.

SCUFFED CYLINDER WAllS

Heavy vertical lines fringed by a discolor9d band caused by metal transferring from one SPOl to another indicates scuffed cylinder walls, The vertical scuff marlcs are caused by metal coming in contact with the piston. The scuffing may be in one particular area or it may occur the entire ktngth of the p iston travel. If this condition eXists. replace the cylinder

sleeve.

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2125-8 CHROME PLATED LINERS The chrome plated liners must not be honed or re-surlaced in any way and only the recommended piston rings must be used. How-

ever, new piston rings may be installed in used cylinder sleeves as long as the chrome

plating is still intact and not physically damaged.

CHECKING CHROME PLATED LINERS Using an inside micrometer. bore gauge or a taper gauge. check the sleeve diameter just below the top ring location and at several points down the length of the sleeve to check taper. If taper is more than .002", replace the sleeve,

The method for determining whether chrome

plating is intact over steel or iron cylinder sleeves is as follows: ,. Remove all soil and oil from inside of cyl-

inder sleeves. Clean with detergents andl or solvents to assure complete removal of oil film.

2. With a cotton swab or clean cloth r8g. wet the inside of cylinder sleeves with Blue Vitriol SolUlion. 3 . Exposed ateel or iron surfaces will be plated a bright copper color. All surfaces that have the chrome plating Intact will not be copper plated. 4. Rinse tested surface with water after test.

Check the cylinder sleeve for out of roundness witt. a bore gauge. Measure the sleeve lengthwise starting just below the top ring location.

WARNI NG. Blue VitI/OJ conUllns ilCId

I\.

AVOid prO/O"9t'd ellposure t o shm Wash off with V'J.ltr.r Protect eves from aCCI dental Slllil~/"n9

If Blue Vitriol Solution can't be obtained from the druggist then proceed to make a satisfactory test solution from copper sulfate crystals which are available at hobby stores and pharo macias. Prepare solution as follows: 1 . Add 1 tablespoon of fresh battery acid to 1 cup water. 2 . Add 1/2 level teaspoon copper sulfate crystals to the solulion. 3. Stir with plastic spoon until crystals are dissolve d .

Check the cylinder sleeve again for out-ofroundness. this time checking points 900 from points checked In step 15.

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.-,~.

-."

2125·9"'"

o C~an

Check bore gauge with a micrometer. If out of roundness ellceeds .001". the cylinder sleeve

the upper and lo_r groove. ' in the

block.

mUfl: be replaced.

Cylinder Sleeve 'Removal and Installation ,,_ STEP 18

Number the cylinder sleeves at alao mark them for position with paint in ,elation to the block. jf the .. me sleeves are going to be re-installed. Use • sleeve puller to remove cylinder sleeves. -'.-- -

IMPORTANT; Befor. removing cylinder st.eves. cover the crankshaft and main bearings::.to.-!",-! prevent sediment from the block. damaging '9" these _parts. - ... "";, ':'_

Lubricate the " 0 " rings with HOM /f30 oil be·

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2125-10

STEP 25 ~!~O'N

Press the sleeves into the bloctc being careful not to damage the "0" rings. Do not ro tate the sleeves during installation . Old sleeves must be instelled in the same position and location as they were prior to ,emoval.

Sl£EVE

PLASTl·G AUGE PIECES

Measure sleeve protrusion at points A,B,C and 0, using plalti-gauge. Place a .001" to .003" plasti-gauge in four positions on the cylinder block Ba shown. NOTE: The plasti-gauge must not protrude onto the cylinder sleeve flange.

STEP 26 A40682 CLAMPING BAR A28312 "., BAll FLAT ON BAll

Cylinder sleave Installed.

PISTON Sl£EVE

CYLINDER ' BLOCK

A142802 CLAMPING DISC

Install clamping disc A 142802 carefully over the cylinder sleeve. Install 1" ball A28312 (with flat side up) and clamping bar A40682. Torque the hold down bolts evenly to 50 ft. Ibs.

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2125-11

STEP 27

\,. \

Remove clamping bolts. bar and ball. Very carefully remove clamping disc being

care-

ful not to disturb plaM;-glluge pH)e8S. NOTE:

Plasti-gauge pieces will stick to either the clamping disc or cylinder block. Before dis1urblng tho pla"ti. gauge piaces. 1hey should be measured and recorded. Sleeve protrus-

ion must not exceed .005", If sleeve protrusion varies more than .005" around circum. ference, change that sleeve and check again.

Piston and Connecting Rod Inspection and Installation

Install flit washers and bolts to hold cylindlt, sl&evlIS in position.

With. bore gauge. measure the 1.0. of the

connecting rod bushing for wear and out-ofÂˇ roundn....

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2125-12 .

o Meas ...,e the bore ga ...ge with a micrometer. If the b ...shing 1.0. meas ... rement is greater than 1.2510", the bushing must be replaced .

STEP 31

Pre., b ...shing into connecting rod until it is fl ...sh with rod. Ream b ....hing 1.2502~' to 1 .2504" if new piston pins are to be installed. NOTE: If a new piston pin Is not being installed, ream the b ...shing .0004" to .0015" larger than piston pin diameter.

o Align the oil hole bushing with oil hole in connecting rod before pressing 1n new b... shing. Using a measure the piston pin diameter.- If outside diameter of pin is less than 1 .2495". replace the piston pin .

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2125- 13

Measure the piston pin bore in the piston in

two places. 90" apart. using 8 bore gauge. If the bore 1.0. is greater than 1 .2508", the

TWO PIECE WITH

piston must be replaced .

OIL FliNG SPRING

Check the aide clearance of the oil ring in the piston with a -feeler gauge. It side clearance exceeds .005", replace the piston .

Break an old piston ring in half and clean the piston ring grooves.

â&#x20AC;˘

SQUARE 'SeCTION

TYPE RING

KEYSTONE TYPE RING (CAN NOT aE

CH'CKe,,, I

Check the side clearance of the second comÂˇ

pression ring using a feeler gauge . If the side clearance exceeds .008", replace the piston. NOTE: The top ring is a keystone type ring and cannot be checked for side clearance.

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Measure tne diameter o f the piston across the thrust face at the bonom of the piston, perpendh:;uJar to tha pi ston pin holea. If the diameter ia Ie.. lkan 3 .9940". replace the piston . STAMPED ARROW

NUMBERED SIDE' OF ROO TO FACE CAMSHAFT

. Assemble tne connecting Make sure the numbenld wards the arrow ,ide of pres.sure only to install

rod to the piston. aide of rod is topiston. Use na nd tne piston p in .

Clean the piston oil nola s witn a amall drill or fine wire .

Install tne piston pin nltaining rings.

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2l25-151!

the piston rings In the cytinder .. . .ve 8?d check the end gap by using a fMler gauge. 1 If. the end gap of the No. 1 compntUion rings la mo .. dUll" .035", replace the rings. If~the and gap of the No. 2 compre..ion rings and 0' the No. 3 oil control rlns.- i. more than ! . Q33". replace the ring.. • ~'J,"" I

M ..aure -the conMCting rod journal. on theJJ crankshaft wfttI a micrometat. Mee.ufO front and rear of each journal , c hecking the

taper. If taper exceeds .OOt the joum... mUlt ba retlnilihed. RtKlhack the rod Joum.... U

9()0

from me

fl~

measure"",nt. for out-of·

roundn..... If out-of-roundness exceed • .0006" • the 'Jouma'. -must be rofinlahed .

...

pinon. In thair" 8.1tP'lnd8f,. Inlbll the bearing liners in tho oonnec:ti"Sl

rod&. Make lure that the kick of the bearing liner engages the lock groove of 1fte c0nnecting rod. Slide liner Into pl.OIl, do not pu.h

in on center of liner.

Rout. the piston rings 10 that the ring end gap. are 1200 apart.

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2125-16

Lubricate cylinder sleeves and semblies with HOM #30 oil.

piston

as-

STAMPED ARROW

NUMBERED SIDE OF ROO

Gently tap lhe piston down into the bl~. IMPORTANT: Meke .ute the stamped arrow o n- top 'of die piston is pointed toward. the front of the"engine·. The connecting rods . are-" numbere.4 "t"co)1SE1.cutlvely 1 through 4 ;01) t!;te bearing ~nd of the rods. The numbers must

Install a ring7compressor on the .;~=:d'Y~;~~~ Make , sure', 1he piston rings are _ fully in the groo\'e. before tightening the ' ring compressor, TIghten ' the ring compresaor_~a little at a time. -making sure the rings are free to compress, -

f~c;~l_';;",)'"'~''' ...;-'

ic .

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2125-17

Install bearing liners into connecting rod bearing caps. NOTE: Make sure the bearing liner lock aligns with the lock groove in _the bearing cap. Use • sliding type movement when installing liners; never press on center of

liners.

'-.)

Install bearing liner cap to the connecting rod. Retain In place with mounting nuts. NOTE: Make sure the number on the bearing cap matches the number on the connecting rod • .

Clean the connecting rod journals and the

bearing liners in the bearing caps. Place a piece of plasti·gauge on the bearing cap liner.

-- ?

... .'-.'

•

• '..

Torque the connecting rod bearing cap mounting nuts 46 to SO ft. Ibs.

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;-. .r'

2125-18

Remove the b.-ring caps and measure the spread out pla.ti-gauge which will be found either on the cap or the crank Journal. Cktarance must .be between .0010" to .0040". If clearance exceeds .0040", unde,.i~e bearing liners mUD' be installed and bearing journals must be reground . ·.r · .

Reinstall bearing caps with matched numbers on rod. toward cams haft and secure with mounting nuts.

--;-

- ;~,.;."

o Torque mounting nuts 46 -to 50 ft . Ibs.

Lubricate the con.necting rod cap liners and rod journals With HDM#30 ' oil.

- .;

Install the engine oil pan and new ga.ket. Torque retaining bott. 10 to 12 ft. lb • .

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2125Â·19

Remove the bolts and wI.he,. retllining the cylinder . Ieeves in plaeo.

Inmll cylinder head and mantfotdl. Refar to Section 2016.

207 DIESEL ENGINE

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Section 2555 ENGINE LUBRICATION 188 and 207 Diesel Engines

J I Case A

renn eco Comp~ny

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2555-2

ENGINE LUBRICATING OIL AND COOLANT SYSTEM

TO OIL FILTER

o o

â&#x20AC;¢

UNFILTERED OIL FILTERED OIL SUMP OIL COOLANT

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2555-3

ENGINE LUBRICATING OIL AND COOLANT SYST EM

•

o o •

UNFILTERED OIL FILTERED OIL SUMP OIL COOLANT ,1 aLOCK

TO ENGINE OIL GALLERY

FROM OIL PUMP

CLEAN OIL FILTER

I:NGI~IE

TO " O IL GA.L LERY

FROM OIL PU MP '

PLUGGED OIL FILTER

2555-4

ENGINE OIL PUMP FLOW STEP 1 Oil is drawn from the engine oil sump by the pump gears t hrou gh the suction pickup tube and enters the pump cavity.

FROM SUMP

SUMP OIL

STEP 2 The oil is forced by the pump gears throu gh internal passages to th e pressure rel ief valve where it dead heads. The oil then flows to the engine oil filter.

FROM SUMP

SUMP OIL

UNFILTERED OIL

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2555-5

ENGINE OIL PUMP FLOW STE P 3 As the oil pressure builds up within the engine o il galleries, the pressure is sensed at the pump . This pressure is then exerted On the back side of the pressure regulator sleeve. As pressure builds up to 50 to 75 PSI, the regulator sleeve ;s moved, opening an internal passage to the inlet sid e of the pump cavity. Should the oil pressure drop below 50 to 75 PSI, the regulator spring moves the sleeve back , closing off the passage to the inlet side the pump cavity.

FROM SUMP

PRESSURE REGULATOR VALVE SUMP OIL UNFILTERED OIL

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Section 3010 FUEL SYSTEM AND FILTERS 188 AND 207 DIESEL ENGINES

J I Case

Rae. 9 Â·78785

PRINTED", U.S.A

A Tenneco Company'

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3010-2

SERVICING THE DIESEL FUEL FILTERS PRIOR TO ENGINE SERIAL NO. 2718490

'-../

FUEL INJECTORS

FUEL TANK

~I~flr~-:~ I i--:'~;:"'~r'~~~ f

(

PRIMARY FILTER

~~ ~

:17 ,..,=:-\-__

, -_ _ FINAL I FILTER

ORilN

FINAL FILTER

jF.\ T \

I TRANSFER PUMP

VALVE

ORAIN

O-GASKET

IDR.,N

RETAINING NUT "\. ._SEAL

c:::::::J UNFILTEREO _FILTEREO rzzrH'DJ RETURN II!!mI!D HIGH PRESSURE

Final Fuel Filter

9 /"

Â©_WASHER ~_SPRING

FILTER BASE

GASKET

Filter Replacement (Final and Primary) .......... Every 500 Hours or earlier when loss of engine horsepower is indicated. Clean the filter side of the engine thoroughlv. Be sure no dIrt is left on the filter bodies. Close the fuel shut-off valve on the fuel tank. Open the drain valves on the primary filter shell and final filter base. 1. Loosen the filter cap until the element and cap can be removed. 2.lnstall a new Genuine Case Filter, new gaskets and place with the 3/4" hole in the filter down onto the filter base. 3.lnstall and tighten cap. 4. Close the drain valve.

Primary Fuel Filter 1. Loosen the filter shell retaining nut until the filter shell can be removed. 2. Uft the contaminated element out of the filter shell and discard it. 3. Wash the filter shell in clean diesel fuel. 4 . ln8tall p new Genuine Case Filter Element in the shell pnd new shell gasket. Check the filter shell retaining nut gasket. Replace if necessary. 5. Install shell assembly on filter base and tighten the retpining nut. 6 . Close the drain valve. 7. Bleed the system and check for leaks.

@.-ORAIN VALVE

:1 I

~ o

'"'MARY _FILTER ELEMENT

~=",,'~ SHElL

GASKET

"-o~~/'-FILTER

SHEll

'''If.---ORAIN VALVE

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301()'3

SERVICING THE DIESEL FUEL FILTERS STARTING WITH ENGINE SERIAL NO. 2718490 8LEED VALVE PLUG_~ ruOL UtolK

t1~:::~~~;;::;~ r;;;;":;::;::;::;:::-·~·O~"...!!"lNG INSET A

.. 0

REM~AL :--.. ,

FINAL FILTER ......... u

Filter Replacement (Final and Primary) - Every 500 Hours or earlier when loss of engine horsepower is indicated . 1 . Close the fuel tank shut· off va lve and remove the drain plug from the primary fuel filter. 2 . Use a clamp type filter wrench or the filter wrench, A64761 Inset A, to remove the filters. Turn the filters counter·clockwise for removal. 3 . Remove the stud gasket from the final filter mounting stud and install a new gasket. 4. ApplV a thin film of clean oil or grease to the gaskets on the new primary and final stage Case filters . Install the filters by turning clockwise until the gasket contacts the filter head. Hand tighten 1/ 2 of a tum. Loosen the filte rs and reti ghten after gasket contact is made. 1 / 2 to 3 / 4 of a turn to obtain a proper. seal. NOTE: Excessive final tightening will damage the gaskets and filters.

PRIMARY FI LTER - -

''''~,:ULV

" 0 " RING- C>

DRA IN

PLUG-~

SEQUENCE FOR BLEEDING THE DIESEL FUEL SYSTEM ~.,

1d>'~"~EED v~\J ' FINAL FIL TER

-;::;,li!!", ~ :."

' PR IMARY_

~LTER

~\. PRIOR TO EN G. SER IAL NO. 2718490 1 . Fill the fuel tank and open the fuel tank shut-off valve. 2. Wipe the top of the final filter clean. 3. Open the bleed valve on the final filter al·

FILTER

STARTING WITH ENG. SERIAL NO. 27184 90 lowing the air to bleed out of both of the fil · ters. When fuel, free o f bu bb les. starts to flow , close the bleed val ve and wipe the parts free of diesel fuel .

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Section 3012 ROOSA MASTER MODEL DB FUEL INJECTION PUMPS AND PUMP DRIVE GEAR 188 and 207 Diesel Engines

J I Case

Rae_ 9 Â·18795

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3012·2

TABLE OF CONTENTS SPECIAL TOOLS .............. ....... .... ................................................. ...... .. .. ... .. . .... ............ .............. . 2 SPECIFICATIONS ............... ............... ... ..... ......................................................................... ..... .... 3 SPECIAL TORQUES ...................................... ... ...... ... .................................................................. 3 GENERAL INFORMATION .............................................. .... ......................................................... 4 FUEL PUMP REMOVAL ...... ......................................... ......... .. .................................................. 5·8 Pump DriVil! Shaft Removal ......................................... ........................................................ 9.10 Pump Drive Shaft Installation ............................................ ................................................ 11 . 12 FUEL PUMP INSTALLATION ............... ............................. .................... ... .................... ... ...... 13·20 Checking Pump Gear Backlash ................................ .................. ........ .. .............................. 21.22 Replacing Pump Inlet Filter ............................................................................................... 23.25 ENGINE SPEED ............ .. .. .. ...................................................................................................... 26 Checking Engina Speed .... ............................................................................................... ..... .. 26 ENGINE SPEED ADJUSTMENTS ......... ....................................................................... .............. 27 No load Govamed Speed .............. ........................... . ... .............................. ................ ........... .. 27 low Idle Speed Adjustment ......................................_........................ ...................................... 28

SPECIAL TOOLS

FOOT POUND TORQUE WRENCH

FILTER WRENCH

A64761

DIAL INDICATOR

SPRING TESTER

SLEEVE TOOL C0322 SEAl COMPRESSION TOOL CD331

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3<112.' SPECIFICATIONS

Fue,l Injection Pump Type ............................................................. Roosa Mester Model DB Rautlon ...............................•........................ ........... Counten::lockwi..

Mounting ..................................................... . Left hand side of englO8

Drive ............................................... Gnr driven at , 1 2 engine s peed Governor ........................................... Centrifugal type. variable speed. ftyweIght. integral

~rt

of pump

Sackllish idler geer to fuel pump gear ............. ............0006 to .007"

.013 to .178mm

lubricetion ............................................. .... ...... Self lubricated by fuel

Thrust Spring F.... length •......... ...... ............. .... ..•....... .....•.. .. ••..•.... .. .........•...... 1 .22"

30.990mm

Compress to .960" f24 .13mml •.•......••••... ... .... .•.•............. 6 Ibs. 4 oz.

2 .72 kg 113.4g

Timing TIlTllng manu ................................................•. . ..•. located on flywheel TIming pointer .............. .......................... L.oc.ted on flywheel hOt»ing

SPECIAL TORQUES Fue' pump drive gear nl.lt ................. ...• .••••• ... .... ....... 40 to 60 ft. Ibs.

64 to 88 Nm

Fuel pump Inlet nut ......................... .. ..... ..... ........ .... ........... 20 ft . Ibs.

27 Nm

Fuel pump mounting nuts ........... .... .. ........ .... ....... .. ... 36 to 42 ft . Ibs.

47 to 57 Nm

Fuel pump high pressure line connector screws .......... ..... ... 36 ft . lb• .

47 Nm

Gaar cove, plate mounting bolts ..... ..... .......... .... ... .... 26 to 30 ft . Ibs.

34 to 41 Nm

Valve cover mo unting nuta .. .............. ........ ..... ............ .. 4 to 8 ft . Ibs.

5 to 8 Nm

. "

.. ,-

,'.'

'.-

". ."

",:.

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30114

GENERAL INFORMATION

considered delicate. the preCISion with which

The Roosa Master Model DB fuel injection pump is an extremely compact and precision

it is manu1actured can be compared to that of

unlt Incorporating a high pressure injection

a fine watch.

pump, a mechanical variable speed centrifugal type governor. vane type fuel transfer pump and Is self· lubricated by the fuel. The function of the fuel pump is to deliver accurately metered quantities of fuel under high pressure to the fuel injectors. This delivery must be accomplished with accurate

liming In relation to the engine firing order and for a very definite period of time in re-

lation to load and engine speed requirements. To meet these rigid requirements, the Model 08 Injection Pump is manufactured to unusually close tolerances. While the pump cannot be

It is therefore doubly important that you take

extra precautions to prevent the entry of dust or similar abrasives when you perform service work that involves the fuel injection pump or other components of the 1uel system. Some pumps are equipped with an external 1ectory adjusted torque control screw. This screw, which is wired and sealed to prevent unauthori:;r.ed changes. provides improved engine lugging ability by delivering maximum torque from rated speed down through peak torque speed.

•

"" CAse '~:"N'~-j~4

...

....

.. •

-.... ...

•

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3012-5

FUEL PUMP REMOVAL

188 DIESEL ENGINE

207 DIESEL ENGINE

o Prio~ -to performing any service work, steam clean the engine thoroughly in -:;i h. area of the fuel -injection pump and lines. Close the fuel tank shUtoff valve. Remov. tt1.-drain plug frOIT! the 'primalY fuel filter to drain .the filter•.

>.,.. ' ." r-:

Crank engine clockwise until TOC mark on fly-

wheel is in line with timing pointer as seen through the flywheel housing timing hole.

o • http://stores.ebay.com/UsefulCDs Remove the breathe", hose,

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C"~n,,,;,~;,i';,;,J;)'.jn«'..~oi..' the Operator's seat)

~st

.. (al viewed

the specified pump timing then. cran'k engine cloCkwise until timing pointer il in line with the specified pump timing mark- on flywh8jtl. This will remover slack f r<:.,m valVe trllin' 'correct pum!1t

timi,ns. NOTE~ R.~ engine v.l,v e. cover or to

data decal't"J n Manual for

specified fuel TIMING """.""

Using filter wrench A64761. remove primary .nd .; .., fuel hood, 'I~r

fi"'" ',om'U""

... p.,,' 'COd. ~

c"'c~'

",Unde, "'cul,

cylinder is on TDC of strote. 'I f both push rods are tight. 380" and again check 'push rods .

':.."

;. -

." r -i'tt!y'

'-,

·~t

·4

·Of".'

• •

Disconnect fuel.inlet line from fuel pump. Disconnect fuel tank supply line from filter head .

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3012-7

R.,.,iv,.'· filter

head mounting ~olts.

Disconnect leakoff ' retum line from pump.

""':-

•~• -,

•

"."

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30''''

•

To obtain the necessary clearance for the fuel pump higl\ pressure fuel lines when withdraw-

Carefully pull the fuel pump rearward, off the pump drive shaft.

ing the pump from the drive shaft, tt i. neeanary to the exhaust manifold. R.. move mounting nuts.

o Remove exhaust manifold and gasket from ·engine.

Any time the injection pump I. removed from the engine for any reason. the two drive shaft .eals and the pilot tube "0" ring seal must be replllcei:l. 'NOTE:' -If fuel pumpi. being '. returned to an Roosa·Master "rvice fstation, i. complete with drive are complete with mounting parts.

Remove pump mo,,:,riting nuts and washers.

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·~

'3012-9~

Pump D'r ive Shaft Removal

Dralncdoling system and disconnect'h-ose-frOm td, wat&r tube. Remove the water tube.

":.'

""W

Remove the cover plate and gaske t .

IIOf:: "J

••

3'TI

•

TIa

Rl!n'IOve thrust plunger.

NO:TE; On aome engines the ' water tube cover 'Plate are one piece. Disconnect hose from cover plate and remove cover plate and g •• ket.

Remove thrust plunger .pring.

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STEP 28

"rHc"

DRIVE SHAFT WITH KEY-

DRIVE SHAFT WITH ROLLP!N

NOTE: There are two types of pump drive shaft. One hal a woodruff key while the other has a roll pin. In event tha shIIft is replaced. thll replacement shaft will contain the roll pin .

...

If the drive pin hal sheered but the shaft II not otherwise damaged, remove roll pin using a 6/64" Easy-Out Extrllctor or a 3/32" Carbide TIpped Drill.

Remove pump drive gear and A new drive pin can be made from an E.na roll pin No. 69-02S-140-.0376 or Case Part No. 13S-275 .. 150" to .146" diameter by 3/S" long. Grind the roll pin flat on one end to the overall dimenlion shown.

·ltt

DRIVE SHAFT

~=i'"....:.l- ,....-1

", 'PIN

-' ~

Pre'l roll pin into shaft chamfered end to the dimension shown ..

--.--

fir.t

'.T "rT'"." ,

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3012-U

Pump Drive Shaft Installation

Insert pump drive s haft into pump drive geer.

Install Iockwe.r end nut on fuel pump drive shaft.

Inmll pump drive gear end thaft. Torque fuel pump drive gear mo unting nut 40 to 60 ft. Ibs.

STEP 31

STEP 34

In.peel thrust apring for the f ollowing : FrM length ........ .................................. 1.22"

TM tim ing me", on the pump drive geer must be aligned with the timing pointM' on the kller geer.

Compres sed (0

. geO ~

... ........ ..... e lb â&#x20AC;˘ . 4 oz.

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,--

'n,ct8'l,o;w"

plate gasket.

Fuel pump drive gear and .shaft install8cr'. front cover 35 to 42 ft.

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•'-~'

3012-13

FUEL PUMP INSTALLATION ~ROTTLE LEVER

NO lOAD GOVERNED SPEED ADJUSTING SCREW

FUel LINE

CONNECTOR

SCR\.

' 1i~'

\~/!. ~ o

~-......:...

COPPER ASH

......

,".

--............. LOW IDLE '"

ADJUSTING SCREW

THROnt.E STOP PLAn:

SHUT_OFf _ADJUSTING

SCREW _ _ _ _ _ _

'\e

LOCKNUT

.~~. '_

f!?

~UT'OfF

_ LEVER RETAINING SCREW

A P\.ATE

GOVE RNOR CONTROL " LEVER

REMOV£ BURRS OR NICKS FROM SURFACE

FUEL UNE CONNECTOR SCREW

'.- .~

STEP 42

CD t2

SLEEVE TOOL

SEALS

Fuel 'pump drive shaft.

Freely lubric.te two new drive skaft . ._Is with lubriphna. Install the seals on sleeve tool CD322 with lips of seals outward. (seals bIIck-

to-back).

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Slide "eeve tool CD322 over pump drive shaft and In~all seals in their respective grooves on the shaft.

If replacing pump, remove the high pr8S$ure line connector bolu and lines from the pump.

o Thoroughly lubricate the two saals with lubTIÂˇ plaUt to avoid damaga and facilitate ease of installation.

When installing fuel line connector bolts into the high pN..ure fuel linas. be sure that two new copper.washers are used on each connection. Make SUN washer. are in place on each side of connector before tightening connector boltl. IMPORTANT; Do not tighten connecto' bohs without tIN w.u,.,s in pl.ce bee.use pump smu,. couJd'" ,sult due to connecto, boh going too de.p Into pump body.

Drive shah seal, installed.

â&#x20AC;˘

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3012·15

Torque CO"f18ctor bolts to 36 ft . lb • .

STEP 49

Using • c/fl.n. wide bladed screwdriver in..ned into the drive end of the pump, r0tat8 the diatributor rotor until the timing lin.. in the timing window are aligned.

IMPORTANT: If

engine hal been cranked after pump was removed. repMt steps 4 thru 6 to ..sure corT&Ct timing.

R.move the timing window cover from injection pump.

IMPORTANT: The rear end of drive shaft I, equipped with. drive tang which h ••• !tole in one aide. This hole must liM up with • heMe ~ted intemany in pump on the diatributor rotor. Tum pump rotor to approKimetely the poaition ung on end of drive shaft so holes correspond with aach other. It holes are not aligned. pump would be 1 BOO out of time.

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o Apply clean engine oil to new pilot tube "0"ring seal and install -seal on pump.

Slide the pump onto shaft being careful not to damage seals during assembly. If rear seal is rolled over on shaft during alSembly, remove the pump and replace rear seal even though no visual damage is apparent. Do not forca After pump is moved forward, It may be necessary to rotate pump slightly to permit tang of shaft to engage slot In pump.

STEP 57

--------

Using seal compression tool C0331 . compress tha seals on drive shaft.

STEP 55 NOTE: When replacing an injection· pump. be sure the replacement pump Is for the correct full load RPM of the engine. The full RPM is stamped on the serial plate of the pump. It would be possible to install an incorrect pump, therefore. always nlfer to the parts catalog when ordering a replacement pump.

NOT AUGNED

Check timing marks in window of~injection pump. If marks are not aligned, proceed to next step. If marks are aligned. proceed to Step 59.

,'I'

•

• -" I

-'""

•

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3012-17

•

" • In the &yent that timing malita 'are not in alignment. rotate pump toward or away from engine until timing marks are aligned. To adva nce timing. n:'Iove top of pump away from engine. To retard pump timing, move top of pump toward

InstaU fuel pump mounting nuta and torque 35 to

42 ft. Ibs.

engi'.'8on top side of -They are calibration marks for Ser-

use only.

o STEP 59_ __

InstalLi naw exhaust manifold gasket. -

aligned

." ..a:.."""

timing;

• ~,

Install exhaust" rn.n'Hold on studs of 'cylinder

head.

"'.

_.... ."

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3012-18

Install e)lhault menifold mounting clamps, washÂˇ ers end nllts.

Torque e.hautt manifold mounting nuts 26 to 30 ft . Ibs.

Connect fuel leekoff retum line to fuel pump.

lnaull fuel filter h.ad on engln. block.

Connect fuel Inlet Ii,.. to fuel pump. Connect fuel tank supply line to elbow of filter heed.

Connect high pNUUN fuel U,... to fuel ~ tora ualng UN one hand-two wr.nch method.

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•

In.... 1 primary Ind flml tu.I hNd. Refer to Section 3010.

'~ "'on.dIt""YlI

C.""'oct the throttle rod to the governor con-

trol. lever and the fuel sIIutcff uble off

Fuel pump

In~.

Inatlill wive cover gasket.

to 1he-.twt-

I~r.

Inst8ll vefw cooter. timing window cover on Injection pump. Roter to Plge 21 and check pump ge.- to id_ gM' backlash.

•

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3012-20

Torque valve cover nuts 4 to 6 ft . Ibs.

Install the breather hOM.

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3012-21

Checking Pump Gear Backlash

Remove water tube.

Remove pump drive ge.r.

,:~

o RemoV9 cover plate and gasket.

.Check idler ge.r to gear. backlash. Maximum backlash .006 inch.

STEP 82

gear to Idler gear backlash using II dial indicator._ Maximum backlash .007 inch. Excessive backlash will cause erratic pump action.

InmU pump drive ge.r. B. sure timing mark on gNr aligns with timing pointer of idler gear.

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3012-22

Connect hOtes to water tube. Fill cooling syst~ .

Inltall cover plate and gasket.

l __';

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.•

• :.,

•

.,~

-~---

,•

.. "

~."

, "

..:-.:

tf1e -::~~tu : '~T~O~"'~",,; mounting.'.,balta -lb.. .•0:

Inltall 26 to 30 -!!"'

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•

- ';-,

. .-

- "

•

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3012Âˇ23

Replacing Pump Inlet Filter

When _rvlclng the fuel pump intet filter, it I. good practive to .Iao change the primary aM flnel fuel filte,... Remove primery and

UnlCrew inkt fitt.f" from fUel pump.

final fuel tilt..... from filter hMd.

Pul Inlet flit. ....mbly from fUIII pump.

Disconnect fu el inlet line from fuel pump.

Remow elbow from fuel pump Inlet..

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3012-24

STEP 91 CAe AND

FILTER ASSEMB LY ·WITHOUT REGULATOR

STEP 92 ":--

,.~.~;.

SCREEN ASSEMBLY O .. RING

Install inlet filter assembly in fuel pump. ©

-SEAL

.,r-;-. ~~l---SCREEN

\:ID

ASSfMBL Y

~ _SEAL

0 _ ' · 0" RING _ -REGULATOR SPRING Q - -PISTON

SEAL

CAP AND FILTER ASSEMBLY WITH R EGULATOR

TOrQue inlet filter assemblV 20 ft. Ibs.

Assemble filter components jf removed. Re place damaged parts. Inspect regulator spring for the fol/owing : Free Length .......... ....... ..... .... .633 to .687" Rate .............................•............ 10 Ibs./inch Color Ident. . .... ... .... ..... .... .. ... ... One end I"iId; one end green

Install elbow in fuel pump inlel.

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•

3012·25

Install new primary and final fuel filters .

Connect fUBI filter line to fuel pump. _

o 188 DIESEL ENGINE

" - ~ "

... '".. •

, """,

,'toe ~~

...

• .,~ 1

"C Ie<

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3012-26

ENGINE SPEED The Authorized Engine SpHd Adjustments described in the following paragraphs of this sectiOfl are for the information and use of

5. Fuel does not meet the required specifications for Number 2 Diesei Fuel.

AuthoriztJd Case Dealers only_

6 . Plugged air cleaner.

Uneuthorized changes in the governed engine speed of the Case Diesel Engine will automatically void end waive any Warranty whatsoever by the J. I. Case Company. Before making any chang.s In the no load governed engine speed. check that the engine speed is not affected by one or more of the following conditions: , . Check to be sure the engine is equipped with the correct injection pump. The pump can be identified by the number stamped on the aerial number plate on the pump housing .

7 . Fuel tank breather partially plugged. S. Fuet filter bleed by-pass valve not closed completely.

9 . Lack of fuel to the injectors due to plugged fuel filters. air or water In the fuel system.

10. Fuel injection pump not timed al described in this section. , 1 . Valve tappet clearance not adjusted and set comtctly. Refer to Cylinder Head SecÂˇ tion.

2. Engine must be carefully "Run-In".

12. One or more faulty injectors. 3. Engine lubricating oil viscosity not according to recommendations. 4.lncorrect 011 viscosity in the transmission or the hydraulic system. NOTE: The transmission and hydraulic oil must be at normal operating temperature before attempting to take an accurate engine speed reading.

, 3.los1 of compression in one or more cylInders.

14. Fuel shut-off out of adjustment.

Checking Engine Speed I\. WARNING: Mahe SUle the power . . . t,am 15 m neutral before checkmg engme speed

2. Hold the tachometer in position until the hand stops moving. Take the reading and double it to arrive at the no load governed engine speed.

Checking engine speeds is critical and can only be made with a tachometer that is known to be accurate. Revolution counters of any type, or tachometers that have been In use for a long time without being checked for accuracy must

not btt used. :...-TACHOMETEfil

NOTE: Refer to the engine data decal on the engine valve cover or to the Operator's Manual tor the engine no load governed speed and rated speed.

Allow the engine to run until the temperature gauge is in the normal operating zone. , . Take the speed reading from the tachometer drive shaft which runs at one half the engine speed. Hold the conical rubber tip against the tachometer drive shaft.

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RuaBEfil CONICAL TIP

3. To eliminate the possibility of error. check the engine speed with the tachometer at least three times.

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.. 3012·27

ENGINE SPEED ADJUSTMENTS No Load Governed Speed GOVERNOR CON"mOL 'F"",_~

I NO LOAD GOVERNED SPEEO SCREW

COUNTERCLOCKWISE TO INCFlEASE CLOCkWISE TO OECREASE

SERIAL .e'M";' ' ....TE

IMPORTANT: Before changing or adjusting the No Load Governed Speed, make sure the engine is operating with the correct Infection pump. The pump can be identified by the number stamped on the Serial Number Plate l0cated 0" the sid!! of the pump housing. 1. Set the engine throttle in the No lo.cl Governed Speed position . The No load Governed speed adjusting screw should be against the pump boss.

2 . lf the No Load Governed Speed adjusti ng ,crew is not against the pump bo.., adjust the throttle linkage until it holds the pump control lever against the pump boss.

3 . lf the No Load Governed speed adjustlng screw is against the pump boSl but the No t.o.d Governed Speed I, ltill low, the speed ~n be increased a limited amount by means of the No Load Governed Speed adjusting ICrew. 4 . To Increue the engine No Load Governed speed by means of the No Lo.d Governed

Speed adjusting screw, loosen the lock nut and tum the adjusting &crew out (counter-

' clockwisej1 / 2 tum at a time and then tighten lock nut. Check the No Load Governed engine speed with the tachometer after each 11 2 tum.

5 . To deena •• the engine No load Governed speed. .., the engine throttle lever In the No Lo.d Governed Speed position . Loosen the lock nut on the .djusting screw and turn the .crew In (clockwise) 1 / 2 tum at a time until the correct No Load Governed engine speed is obtained . Check the No Load Governed engine speed with a tachometer after each 1/ 2 tum. IMPORTANT: The No Load Gove rned Speed .djusting screw is sealed with a wire and lead aeal. You muat have the necessary equipment to rese.1 the adjusting screw when the adjustment Is complete. Always make a record of the date you broke the seal, the seri.1 numbe, of the machine or engine and the reason why you bn*e the seal.

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-~ 3012-28

Low Idle Speed Adjustment -,'OOV,.,'O. CONTROL lEVER

TO CLOCKWISE INCREASE

lOW IDLE SPEED

o Set Speed ernor screw

the engine throttle in the_ Low Idle position. Check the position of the govcontrol lever. The Low Idkt Speed should be against the pump boss.

If the Low Idle Speed screw is not against the pump boss, adjust the thronle linkage rod until it holds the control lever against the boss. ' "

engine speed with a tachometer after each 1 2 tum of the adju~ting screw.

- by means of 2. To incrtl"se the engine speed the Low Idle Speed adjusting screw. loosen the lock nut and tum the adjusting screw in (clockwisel1/2 turn at a time. Check the engine speed with a tachometer after each 1 / 2 tum of the adjusting screw.

If the Low Idle Speed screw is against the pump boss but the engine speed is not correct. the engine speed can be increased or decreased I limited amount bV means of the low Idle Speed adjusting screw.

IMPORTANT; 'The low Idle ' Speed adjUsting

1 . To decre. ." the engine speed by ,m.ans ,.of .the Low Idle Speed adjusting screw~ loosen _the.lock nut ,and turn the screw out.Ccounterclockwisel 1 12 tum at a time until the correct engine speed is obtained. Check the

screw is sealed with a wire and Ieee! seal. You must have the necessary equipment to reseal the adjusting ' screw when the adjustment i. -complete. Always make a record of the date you broke the_ seal. the serial number of the engi~e ! nd ~e re.son why you bro~e the seal.

';'

NOTE: The

eo-

Com,...,.., _

3. After the conect engine speed is set. tighten the lock nut while holding the adjusting screw setting.

,...

In d-.ign Of . . . . . . . . . . . .. . . .ifIc4mem a' any Hligali .... 140 In ...... , .......... u.. ito ,.......;-sly .... d.

nth, ,,,-

'e ....... i"'....-.... with.o,

............

any

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Section

3013 ROOSA MASTER FUEL INJECTORS

188 and 207 Diesel Engines APPLICATION Pan

Num~

Color

Roosa MUle.

'"'

Code

Engine Application

Ban~

A37836

17206. 18054

No . - .

1\1;0970

20652

No Colo.

,0>

AS1234

19993.20348

No Color

A140827

20074

..,,40828

20673

1Nh1t" &. V"low

AI40829

20671

Whito

~ ..

,0>

&B_

'" '"

SPECIFICATIONS P.t1 Number>

Aoo ... M ...o,

"'37836

17206 .1806 4

20552

A50970 A'40827

20674

A512.).4

19993.20348

Sprey Angle

",. "'"

"'"

"t 40829

20671

HIO'

A14D828

20673

"',.

J I Case

SJ>ray OrifiQ Size

Opening P"U5ur"

Hole

Hoi"

...,~,

Sl~"

o."

2760

2550

.. .. ..

2660

.011" 1.279mml

.195"

.042"

(A..963mm)

(1.068mml

. O11 ~

.O95~

(.279mm)

12 .413nvnl

.042" (1.0156mm)

.O11~

. 095"

.042 W

(.279mm)

(Z.413mm)

•• 2860 (18958.SkPa)

1t7 579.1kPa)

11.066mmJ (19 647.9kPal (18269.1lr.Pel

.095"

.042"

(. 279mml

(Z.413nwn)

11.086mm)

.011'· (.279mm)

. 096·' (Z.41lmm)

.042·· (1.066mm)

(22 4015.l5kP,,) (21 026.7kPa)

.010'·

.095'·

.042"

'760 10 28S0 to 2650 ,18958.5kPa) 117 579.7IcPa)

1.2S4mml

(2.413mm)

11.065mm)

.01 '"

RII<:. 9 · 711805

3150 to 3250

2960 to 3050

121 716.1kPe) 120 337.3JcPa l

119 647 .9k Pa) (18 269.1 kPal

""HlEO IN USA

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3013-2

WARNING When restmq or ild/ustmq

f uel tnlt!ctC}fS do nor place your hiJnd~ Of auns In front of the "'jcctor nOTrli'

charge of an injector, apply the follo wing first

aid immediately and then have the injury examined by a physician as qu ickly as possible.

The fuel spray from an injecto r has sufficient

Wash the injured part with boric a cid soiution,

penetrating power to punct ure the flesh and destroy tissue. Should the fue l enter the blOOd s tream. it may cause blood pois oning .

and sling so the injured part will remain absoIutety at rest until a physician can examine

In the event the skin is punctured from the dis-

support the injured finger or hand with a splint

TABLE OF CONTENTS General Information .... ... ................ ... ................ ... ...... ............ ..... ...... , ........... ... .................... ....... 6 Injector Adjusunents .. .. ................ .... ..................... ..__................ .. _.................. ... _........... ........ 22,23 Injector Test Stand .. .................... ......................... .. ..................................... .............................. 13 Installing Injectors .......................... ........................... _........................................................... 10-12 Isolating Faulty Injectors ............... ...... ....................................................................................... 8

Nozzle Identification . .................... .. .. _............................ ...... ........ .... .... .......... .... .................. ........ 5 Operating Principles ... .... ......................... .................... .. ............ ... .... ............. ... ........ ..... ,............. 7 Removing Injectors ... .. ................ ....... .................... ..... .............. ....... ............. ..... ...... .. ........... .... 8,9 Servicing Injectors ............................ ...................... ........................ ................... .................... 16-21 Special Tools ................................... .. .......................................................................................... 3 Special Torques ...................................................... .. .... ........................................................... .... 4 SpeclIlca tions ............ ............... .. .............. ................... _............... ......................... ..................... ... 4 Testing Injectors .. ...... .. ........ .... .... ..... .. ............ ....... .... .. ............... ................. ..... ... .......... ..... .. . 14,15

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SPECIAL TOOLS

•y •

TORQUE WRENCH

AD"""'. SII·Ol.15

VAlIfE RETRACTOR 815·0148 ORIFICE CUANING

mites

1515·0036 COMMiSSION

SAC HOLE DRilLS SET OF S

.01lY' 1e·01ll1

SEAL TOOL CASE PART

••2«9

TIP SEAT SCRAPER

GAUGE .DAPTER 70-31. 105581

00· 0148

TEST PUMP ADAPTER 155-878 ""1

LAPPING

IN,J~Olt

COMPOUND

HOLOING TOOL

MAGNIFYING GLASS

1e..o1.6

811-01.7

158-0136

TOOLS IN CASE KIT NO. M20620 The individUlI pans can be ordered from the Bacharach Inn. Co. 200 N. Bqddoc:k Ave., Pittsburgh. P• . 15208.

......

•

_. ~,

'-'

•

,~.

601"'! CLfANINO TOOL CASE PART NO . ...3277

TEst ST .... NO CAse " .... RT NO. W0322 B.... CHARACH PART NO. 156·9340

NOULf PULUNG TOOL CAse PART NO. 'A43278 '

NOTE: Ini&ctor Tool Kit. Case Part No. M20520. Bacharach Pan No. 60·001 O. This Idt is used in conjunction with the Case Diesel Tool Kits, Case Pan No. M20247 (CD· Baal and C...

Part No. M20246 (CD· 350).

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3013-4

SPECIFICATIONS U.S. Value

Metric Value

No. of orifices ................................................................................ 4 Valve lift .......................................... 009" or 112 tum off valve seat.

.229 mm

Nozzle leakoff rate ................................ 3 to 10 drops in 30 seconds

at '600 PSI after first

10 341 kPa

drop appears (serviced injector). Maximum opening pressure between cylinders ....................... , 00 PSI

689.5 kPa

Opening pressure control spring:

INJECTOR NO.

COLOR

SPRING

CODE

FREE LENGTH

NO. COILS

.563" (14.3mmJ

.05S"

.276"

7.'

(1.47mml

17.01mmJ

.536" (13.61mm)

.056" (1 .42mm)

.272" (6 . 91mm)

WIRE CIA.

0.0.

COMPRESSED

A60970 A61234

A140827 A140828

.456" to .478" at 29 Ibs. (11.58mm 10

12.14mm at 13.2 kg. )

A140829

NO A37836

COLOR

.435" to .467" at 27 Ibs. (11 .06 to 11 .61mm at 12.3 kg. )

SPECIAL TORQUES Fuel injector clamp capscrews ................................. 18 to 22 ft. Ibs.

24 to 30 Nm

35 to 45 in. Ibs.

4 to 5 Nm

Fuel injector pressure adjusting screw locknut .......... 70 to 75 in. Ibs.

7.8 to 8.4 Nm

Fuel injector tube nuts .. ..... ..... ........................... ...... 18 to 22 ft. Ibs.

24 to 30 Nm

Fuel injector leakoff nuts ,......................................

Fuel injector valve lift adjusting screw locknut ......... 40 to 45 in. lbâ&#x20AC;¢.

4.5 to 6.0 Nm

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,., NOZZLE IDE!ljiTIFICATION

., : 3200 PSI OPEN1NQ PRESSURE

2800 PSI OPfNING PR ESSURE '. SINGLf lOCKNUT lONG NOZZU PART NUMBER LOCAnON

SHORT TIP

NOZZLE I'AAT NUMBER LOCATlON

o•

....

PART NUMBERS

, .... 'f

. .;.

.,40S29

... ...

PA RT HUMIERS

A37838

~'l'

.1l'K> "

",-!

",~

"' ,..

••

"',hl

•

""1';1

2800 1'81 OPENING PRESSURE

·L~O~TI'

--,

...... .....

... 234

SEPARATE LOCKNUTS >

NOZZLE PART NUMBER LOCAnON

....'"

, • ,

PAnT NUM8ERS"

A140828

•

• ~~"1+-, .

'"31' ; ~~.> .., ..,;,....... .,'.~.

0:-.

~~..;

· ........ ~.t..,...·

... -

•

i)l.,O".'"

.....! •• .:.."

..~ tfO!'.

••

'r_

~,tl

•

"" "Ai

•

..... .. ......

'-; .... '

, ..•

" •

•

A140827

•

•,

•• :.It..

... j

.. '- , (j:~.

,·l. -,. .~,·

-":"

•

.,!"\ .......J •

,¢

, "

.. . ,

·.i

'..'''''

•• "':1

!.!."

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3013-6

GENERAL INFORMATION The fuel injector is a closed end (injector valve does not project through an opening in the injector tip) differential pressure, hydraulicillly operated hole type injector. The fuel injector s are located in the cylinder head - one for each cylinder. It is the fun ct ion of the fuel injector to direct a metered quantity of fuel received from the inj~tion pump to the combustion chamber. Each charge of fuel must be delivered into the combustion chambe r with a definite spray pattern to insure comp lete combUstion and efficient engine per· formance .

IMPORTANT: The injector bod y and va lve is a mated assembly. accu rate ly tapped to a very cl ose fit for prec ise metering of fuel to each cylinder. The body or valve ca nnot be installed individually for service . If it is necessary to replace aither t he valve Or body, replaca the complete assembly_

prevent sticking. INJECTOR VALVE . Controls the flow of fue l from the injector _ VALVE GUIDE - Supports and guides the movement of the valve in the body . OPEN ING PRESSURE CON TROL SPRING • Controls fuel pressure necessary to lift the valve from its' seat. PRESSURE ADJUSTING SCREW · Compres· ses tne opening pressure control spring to maintain a predetermined spring pressure on tna va l v6. LIFT ADJUSTING SCREW · Controls the valve travel distance_ INJECTOR TIP - Contains the valve seat and four spray orifices which direct the fuel spray in the combustion chember.

IMPORTANT: 00 not m ix v alves and bodie, white disassembling the injector.

CARBON SEAL - Prevents carbon accumulation in the cylinder head openings.

INJECTOR BOD Y - Houses t he injector parts in their correct position in the cylinder head. The part of the injector body which proj ect. into the cy linder head is Teflon coated to

COMPRESSION SEAL - A ny lan se.1 under the inle, fitting that prevents engine com preuio n 'ukage.

ADJUSTING SCREW

--.~~~ '".< ADJU STI NG SCREW

..-' ' ' ' ' ADJUSTING SCREW - - ,•• ,,,,,",,, ADJUSTING SCREW

UPPER

-:::'~:::;N'W~';;AS HEfi PRESSURE

... _ _ O. <N'""" PRESSURE

SEAT

CONTROL SPRING

CONTROL SPRING VALVE

G""O"~

VALVE .,,,0'--

SEAL

~:::::~=>"N'''C'O.

SEAL

80DY

CARBON ' ' ' ' ' - -

s<.u-_

CARBON

- 'N."'''').

~-'''''''C",'. VALVE

~'S'.AY

VALVE

ORIFICES

SPRAY ORIFICES A51234

A50970

A 140B27

A 140B2B

A378311

A1<W829

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OPERATING PRINCIPLES The Optlflltion of the injector is simple lind

The

positive.

pressure

A metered quantity of full under high pres -

sure from the injection pump flows through the inlet line of tha injector arOund the in路

jactor II l lve . At the instant the pressure of the fuel Iglinst the v81ve exceeds the predetermined spring force, the "'Ilve is forced from its' Mat al路 lowing IUII I under high pres.ure to flow through the four spray orifices to the combustion cham路

be,.

VAlVE

instant

the

;!I911in,t

fuel the

daHve,..,. valve

ceall8l.

tht

reduced

lIoe

the control spring snaps the valve to its' seat This 81imine te. any possibility of drippin ~ after the metered amount of fuel hll blten de livered. In Ictual operation. the velve open: and CIoS.1 V8ry rapidly with II d istinct chatter During injection , II small amount of fuel leek, through the closely controllod cl .. ",nce II the guide. lubricating all the moving parts ir the injector. This fuel then flows off throug l leak路otf lines at the top of the Injector 81" returns to the fuel tank.

",,'';ONO PRESSURE CONTROl SPRING

FITTING

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ISOLATING FAULTY INJECTORS STEP 1 If the engine is misfiring and one or more of the injectors is suspected. the followi ng procedure. c.n be utilized to isolate the faulty injector.. NOTE: The engine should be run at

• speed where the misfiring is most

.p~rent.

Using the one-hand, two-wrench method, loosen the fuel inlet tube nut for the number one cylin -

der injector . If the injector is faulty, there should be no notieaable affect on engine parfonning. Tighten the inlet tube nut using the one-hand, two-wrench method.

p,o.",-';'''; ;;n;;~,",ie, seq uence for the remaining Injector•.

R ....'

REMOVING INJECTORS

CI.a n cytinder head ar.a around injector.. Dis-

Remove the injector t ....

connect the leak-off line nuts.

Remove the 'leak-off Un••.

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Disconnect the inlet fittings uaing the one hand, two-wrench method.

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3013-9

loMen Injector cl.mp auemblltlS.

Remove the injectors by pulling upward and turning . IMPORTANT: Never .ttempt to ,.. mo .... an injector by prying with a screwdriver or similar toot If an injector cannot be ....,., 'emo....d by hand, proceed to Step 10 ,

R.move the clamp ..sembl_ and t:p&cers.

Ramove tha

inJ.ctors using

nozzle

C... Part No. A43278.

R."IO".

the tee nUtl from the Injacton:.

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pul. .,

INSTALUNG INJECTORS Clean and inspect the cylinder head. injector inlet fittings and seal surfaces. Dirt or burrw on the sealing surfaces can cause injector distortion when clamping injector In place, resul· ting in a lltiddng valve.

Squirt a few drops of clean engine oil in •• cl cylinder head injector hole to provide lubricant for carbon dam at lower end of injector when being installed.

CI..n cyfinder head injector bore ullog bore cie8n8f. Ca.. Part No. A432n.

InstaU injectors into cylinder head bores using

• twisting motion .

Always tum tool clockwise. Counter·clockwise rotation dulls the tool. Blowout with compres~d air.

Install injector tee nut.

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301 -11

TEP 16

Insta ll spacer and clamp assembly, engaging lock plate.

STEP 19

Install injector tee.

STEP 20

Install leak-off lines. Torque clamp assembly bolt 18 to 22 ft. Ibs. (24 to 30 Nm)(2.4 to 3.0 kgm)

STEP 21 STEP 18

Tighten the leak-off line nuts . C onnect and hand tighten inlet connection to tube.

Rae 9-78807

3013-12 STEP 22

STEP 23

To bleed the ai r from injection tubes, loosen the inlet fIttings and crank engine until fuel flows from he in let fitting. Then tighten the inlet fitting using the one-hand two-wrench method .

Start engine and check for leaks.

Rae 9-78807

3013-13

INJECTOR TEST STAND Fuel injectors must be checked on the t65 stand when performing the following servlc operations; 1. Whenever an injector has bean removed from the engine for cleaning. he inj ector must be checked on the test stan prior t installing it on the engine

2. When a new injector assembly is to

e installed. it must be checked 0 t e test stand prior to installing it on the engine.

An " Approved " Injector Test Stand . Case Part No. M20322 I.Bacharach No . 65-9340). is required for testing and adjusting the injector and can be purchased through the Service Parts Supply, J . I. Case Co .. Racine. Wisc . Except for descriptions referring especially to adjustments on the test stand itself. all of the following instructions will apply to all makes. Operating instructions are also fur nished with the test stand . An injector too'i kit, Case Part No. M20520 Bacharach No. 60-001 0), is required to service the injector. A compression gauge adapter. Bacharach No. 70 -314 (0-568) is also included in the 001 kit. This ki t is used in conjunction with the Case Diesel Tool Kits. Case Part No . M20247 (CO -S aO) and Case Pan No. M20246 (CD-3S0). The test stand is used to perform the following checks : 1 . Check and adjust the '"lecto r opening pressure. This is a duplicate of the factory procedure. 2 . Check the injector assembly for fuel leakage.

3. When a complete engine overhaul is performed. the injectors should b re oved and Checked on the test stand. 4. When an injector is suspected to be the caus of unsatisfactory engine performance. it should be removed from the cylinder head and checked on the test stand prio to disassembling it. IMPORTANT: ALWA YS CHECK .~ E PER ~ O RÂ MANCE OF AN INJECTO R ON THE T T TA D BEFORE DISASSEMBLING IT. IF- IT CHECK OUT SA TlSFACTORIL Y, THERE IS N NEED TO DISASSEMBLE OR ADJUST IT.

Preparing Test Stand 1. After filling the test stand f uel reservoir. loosen the bleeder screw . 2 . When the fuel flowmg from the bleeder screw opeOtngis free f ai bubbles. t,ghte th e screw. 3 . Wash the connector ube and dapter in elea diesel fuel. Blow clean with Iltered com pressed air and connect securely to he est stand.

3 . Check and adjust the injector leak-off. 4. Accurately check the inject or spray pattern.

4 . Operate the hand lever slowl fuel flows from the adapter

until clean

5 . The test stand is now ready for use. NOTE; Complete operation and maintenanc Âˇnstructions are furnished with the est -tand . Follow the instructions c arefullv.

Rae 9 -78807

3013-14

TESTING INJECTORS Pri or to testing an injector, remove the loose carbon from the tip with an injecto r cleaning brush. C lean the carbon seal groove and body below the groove in the same manner. IMPORTANT: 00 not scrape or brush the Teflon coating above the oarbon seal groove.

Do not attempt to connect the injector inlet fitting d irectly to a standard Ermeto or 60Â° swaged type line as damage to the tubing can result.

Checking Opening Pressure Close the pressure gauge valve and flush the injector by operating the test pump rapidly . Open the gauge and raise the pressure slowly until the in jector valve opens. (The gauge reading will drop sharply at this point) . Check opening pressu re against the specifications .

NOTE: When testing more than one injector out of the engine, there must not be more than 100 PSI difference between any of the injec tors in the engine. If the injectors do not meet the specified opening pressure:

Using the test pum p adapter Bacharach Part No. 65-878, connect the injector wit h the tip fac ing downward .

TEST

UM P ADAPTE R

6&-878 {N49 )

1. New injectors can be adjusted to the specif ied opening pressure. See Page 22. 2. Injectors that do not check out on the test stand should be disassembled and cleaned. See Pages 16 th rough 21 . 3. Valve life screw may be out of adj,ustment. See Page 22. 4. Check for broken or w eak open ing pressure control spring, see specifications.

Checking Seat Leakage Point the injector tip down and operate the test pump rapidly to firmly seat the valve . Dry the injector tip thoroughly. Raise the pressure at the injector 200-300 PSI under the specified opening pressure. A drop should not form on the tip within 10 seconds. Slight dampness, however, is permissable with a used injector. If drops form on the injector tip, the fol lowi ng should be done. 1. Disassemble and clean injector, Pages 16 through 21. 2. Valve is not free in guide. Lap valve to guide. See Pages 18 and 19. 3. Inspect for pitted or cracked valve tip, eroded valve seat or pitted and distorted body . These

conditions require replacement of the complete injector assembly. Rae 9-1Se01

3013-15

TESTING INJECTORS (Continued) Spray Pattern C lose the pressure gauge . Operate the tester at 60 stro kes per minute and observe the spray pattern . Fuel shou ld be finely atomized and not a solid Irregu lar spray pattern .

1. Check for eroded, c log ged or chipped orifices. See Page 18 .

2. Disasse mb le and cl ean injecto r, See Pages 16 through 21. 3. Lap the valve to guide area . See Pages 18 an d 19.

4 . Check for pitted or eroded valve or seat. valve interference angle worn , bent val ve and distorted body. Th ese condi tio ns w ou ld req uire replacement of the com p lete injecto r assembly.

Injector leak-Off

Fine Atom ized Spray Pattern

Loosen connector nuts and repositi o n injector t ip slightly above a horizonta l plane_nghten c on nector nuts and raise pressure to 1500 PS I. O bserve leakage from the return end o f the Injector. After one drop falls , leak- off shou ld be 3 to 10 dro ps in 30 seconds with No . 2 diese l fu el at room temperatu re

(65Â° -75Â° F.) .

Solid T ype Irregular Spray Pattern

T h e Injecto r wi ll chatter when the tester is operated rapi dly . Although this ch atter may not occur in operation of the injector in the engine, it is an Indication of val ve freed o m and wi ll improve atomIzation. C h tier is generally an indicat io n of good eat w idth and in terference angle conditions.

he injector p roduces f\ solid type irregular spray pattern , proceed as follows : Rae

788 7

If the leak-off does not meet th is spe cif icat ion , proceed as follows: 1. If excessive leak-off is no ted , injector must be replaced. 2. If low leak-off is noted, d isassemble and c lean injector , See Pages 16 th ro ugh 18 . 3. Lap the valve to guide area to increase th e nozzle leak -off, See Pages 18 an d 19.

•

3Ol3-16

SERVICING I'N;JECTORS ,"~ ., Disassembly Because the injector contain. ciosely fitted perU whiche", prea.ion ground andfinilheci. dtrti.Ita' ;. greatest lHWmy. Exercise utmost care In keeping the work eroe and tool. clean. Hartdle all peru carefulty to evold damage.

Remove MId dl8card carbon dam

...a. .

STEP 26 ,.,.~;

...

INJECTOfI; HOLDING

TOOleU'47

,< ·Rtace Injector In the holdlno tooI'o.BachliKh Pan No. 88·0147 and MCU,. the tool in ... viM. Loo ..n the preaure ~ne ac..w·Iodcnut. " ~ .' • '

Remove anct!'dlseard compreHion .....,~.

.:;;

• .",,_.

allowlot the.apring YO."" ...othar hand . . t .... ·.·

•

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3013-17

STEP 28

If the valve does not slide freely from the body, use valve retractor Bacharach Part No. 56-0148, to remove the valve. To prevent bending the valve, bottom it in the body with the retractor. Push down on the retractor body to mount the collet. Turn the knurled nut counterclockwise to secure the collet and withdraw the valve.

The valve may slide out of the body at this time and should be handled carefully by its' stem. LIFT ADJUSTING SCREW LOCKNUT

LIFT ADJUSTING SCREW

LOCATING

PLAT~E\~/( --- .-

\,~

'I}

ยงJ~

/ I /

-- ~ ADJUSTING SCRE~1 -- _ PRESSURE

~ ( ~

_~ PRESSURE ADJUSTING SCREW

/ INLET FITTING

SPRING

'INJECTOR / /

~ SION

SEAL /

COMPRESSION SEAL "'"

VALVE

A50970 A51234 A14082J A140828

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WAS"ER~ ~\

LOCKNUT

no.

UPPER"'--~ PRESSURE SEAT

ADJUSTING

--..

SCREW "-

SPRING

ยฃI!b.

LOWER SEAT /

CARBON SEAL .... _ J

/ /

............ SEAT

COM PRES -

~~4t tlU

'BALL

,SCREW

'-...

BODY

' ) ADJUSTING

"PRESSURE ADJUSTING SCREW LOCKNUT

INLET FITTING

LOCATING PLATE

CARBON SEAL

/ / "-

-- - J

A37836

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3013-1!!

SERVICING INJECTORS (Continued) Cleaning and Inspection ,. All parts should be pl.!llced in a solvent to loo&an c arbon deposits. 2. A brass wire brush should be used to chum the tip and body exterior. To clean carbon from spray orifices, use cleaning wires Bachlrach Part No. 66-0036 in .010". .m 1 ", and .012" diameter. Secura the wire in a p In vise with the end protruding 1/ 32". A longer length of wire will bottom on the opposite wall of the sac hole and tends to break euity.

the valve in a motor driven lapping lath. for clelning. as this technique will bend the velve. Inspect the valve for pitting or erosion which could causa leakaga.

6 . Inspect tha adjusting &crews for thread damag. and replace if necessary .

0&-0143

SAC HOLE

16路 0151 DRILL

ORIFICE CLEANING WIRES 66-0036

TIP SEAT AREA "Oil

Reconditioning Injectors If simple cieaning does not restore an Injector to proper operating condition, lise the methods outlined below:

Usa a stone to remove cutting burtS from

the end of tM wire. If a s mall flat is stoned on one .ide of lhe wire it will facilitate cutting

carbon from the orifice . Insert the cleaning wire and rotate il until it is free . Flush the body and inspect the lip . If any orifices Ire chipped at the adg'" Or e.oded to an extent that apray pattem is aHeetad, tha injector should be replacad. 3 . The seat area in the tip can be clelned uaing the tip saat sc raper tool Bacharlch Part No. 66-0149. 4 . ln... rt MC hole drill Becharach Part No. 86路0161 into the :woe hole, rotate it to cle.n deposlu from the sac hola; repeat orifice claaning. S . The injaetor ",Ive may be cleened with a brush to remove deposits from the seat al'88路 Varnish should be removed with 8 solvent and fell cleaning pad . Do not chuck

, . SEAT LEAKAGE 路 If lack of freedom of the valva movement ha s been ruled out es the cause of saat leakage, the velve may be cleaned up by lapping it to the tip seat. Use lapping compound Bacharach Part No. 66-0145 . for this purpo . .. The purpoae of lappin g i. to polish the seats of both valve and tip to obtain i! tight ...1. Exc'ssiva lapping witt destroy the interlerenee angle between the seat and valve, causing a loss 01 chatter wlln poor atomization.

:J.---

VALVE

TIP SEAT

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SERVICING INJECTORS (ContInued) Place • amall amount of lapping compound

aecfl.rKh Part No. 66·0146 on the valw ...t and Interl: valve Into the body. Grip the top of the yaw. with the ret ...ctor Bacha,.ch Part No. •1..:0148. ROUte the valve by hand. flm dockwiM then co nttIf'ClockwiM for a total of 3 - 5 reY04utiom. IMPORTANT: Never attempt to UM motor driven chucks of any kind for thie purpo... Flush the body thoroughly. Wash the vatve and reassemble injector.

TM -injeetor may be then i.teated. If the yafw- and ...t is worn. the ...t. mIIy be tight. but ct.t18r may be lost in the "pping ptocell, In such c.... the injector mud be repJ.ced. 2. VALVE GUIDE SERVICING: Low return Ieak-off ia an indication of varnish KCUmua.tion betwften the guide and valve. InllUfficient ckt.rance ClIO CIIU" sticking and kHa of chatter. If retum tNk-off I. found to be betow specified qu.ntitiM. the vatv. guide cle....nce mIIy be inctMsed by lap. i ....

P!aoe • IRWA M1CMM'It of iIIpping compound B.ctu.rach Part No. 88·0145 on the guide a,.. of the varve. Bottom the vaM in the body and grasp with the retnlctor . . pNViousIy deacribed. Route the valve ten revolutions whIe ,..ng and lowering it '*Y allghtty. Flueh and ~ah compound from both components. Auemble and ...check return ".k-off.•f .....-, off ia "'U low. lap the gukl_ until correct 1Mbg_ i. obtained. Atw..,. flu .. the injector thoroughly .fter lapping. IMPORTANT: The required .mount of 1nIIteritl removed i. uSUIIlty only e few millionth. of en Jnch. Never UN motorized chucks; for this oper.don.

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.- . SERVICIN9 INJES;TOR <!'A ssemb,ly:

~Conti'm,d

•

and flush all parts thoroughly before .s·

t.r::~;,;w~at

all in,ieetor parts and hands with

during assembly.

Install a new compresaion seal.

,. '''-" STE~~ ~3~~~'_'~__ ~ _'_~__' _ ' ____--, ;:.:~ f...."" -..~.

.kl· c';t · ~rti ...

::.~'n:i"';';;;'••' the thalocating preuure

on tl).a

adjusting

....

CARBON SEAl. TOOL A42449

.,... ..

.\-'

..., 'OW

Install a new carbon dam seal using the carbon .seal tool. e ... Part No. A42449 .

.... mbl. spring. ball washer and upper spring Hat} on the lift and pressure adjuating screw assembly. Tift -the injector body and with the apring Hat contacting the valve top. puah the v.va and spring components into the body. Exercise c.re not to dislodge the spring . .at during thia ....mbJy. Thread the pressure adju.-:ing screw into the body by hand until the .pring is compreued aufficiently to hold all parts in place.

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3013-21

I..~II injector assembly on the- test stind: Test and adjust opening pressure valve lift and leakoff. See Page 22 for injector adjustments. .

TIghten loCknut 70

75 ' inCh 1M.

LIFT ADJUSTING SCREW LOCKNUT UFT ADJUSTING SCREW

1-' '"

LOCATING PLATE

/ /

,, ( _

WASHER

I -

/ INLa / -RmNG / UPPER

~."'N.

.SEAT

'--

SEAL VALVE

CARBON SEAL / {

"--'

AG.970

"'234

""-~

CARBON SEAL

SEAT

/,.I!

/'"

LOCKNUT

'lIi "

,SPRING LOWER SEAT

""-

~" / e

SCREW

COMPRESSION

PRESSURE ADJUSTING

PRESSURE ADJUSTING ""'] SCREW

COMPRES- / ~SI0N SEAL

..... PRESSURE ~_ _ ADJUSTING SCREW LOCKNUT

.INJECTOR . / BODY

LOCATING PLATE

"'"

/ /

LIfT ADJUaTlNG SCREW

I r---~VALVE

/ / A37S38

A140827 4140828 A140829

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-•

3013-22

INJECTOR ADJUSTMENTS

'- ,

Adjusting Opening Pre.aure INJECTOR HOLDING

TOOL .-0'47

3. Back out the Ittt adtuatint screw OPe full tum. •• While pumping fuel through the injector. note the opening jHUaUre. Tum the prlssure .d-

justin" acNW. white holding the 11ft adJ...-ting acrew,ciockwiM to Inc ...... opening pmsure or counterclodtwi.. to lowI' the opening prenure. Do not tighten the preaure actjustlng locknut at thla time. tH't .und and ..cure in holding tool, alChaflCh Part No. 88.Q147. In I vi ... Loo..n Ih. p,....re _d· ju...'ng ICNW lodcnut.

1. Ramo.,. the Injector from the

un AD,JUSTlNO ICAEW lOCKNIIT "ESSUAE ... DJUSTlNG............ SCREW LOCICNlIT ...........

Setting Valve Lift ,. WhU. pumping f ....' through injector. hold the preulJre adjusting KleoN and .towtv tum lift Itdjul'tlng screw cJockwi.. until wive c.....

to_.

2. Check for bono",'ng of the v.t .... by rlilling the preuu ... 200-600 PSI over Injector Gpo eni"9 preMU .... Atthougtl ...". fuel mly c:oIlect on the tip•• rlPid dribtM lhould not be .pp.....m:. Do rIOt mIInUolll1y bottom the valve with exceuiYII force .. bending of the v.tve c.n rHulL 3. Tum the 11ft Mljusting x,..w counter-clockwi.. 1/2 of I rum to owin the specified lift. Hold the lift Idju'ting sentw end tighten the lift IcI;usting screw tocknut 40 to 46 in. 1bI;. U . . Snip-On Tool 1/4" Crow.foot W.-.nch No. AN9608-6 end, In. lb. torque wrench.

4. Recheck the "'Plning preuurl. Note thlt the lift ia _t baton ohecking .pr.y p.t_

tern and cNittel" ,. the 'mount of lift wiD affect thlM chlracteristic..

2. Loosen tfMI vatva 1111 adjultinv .crew locknut H ~ui"P"i. whil. holding the WM lift adjultlng .cRW. Then Ntconnect the injector. with the tip downWllrd onto the test stand. Part No. M2032Z:

c...

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Tightening Locknm TORQUE WRENCH ADAPTER 66. 0148

Remove the Injector from the .ett stand end pa.ce In the holding tool In viM. Tightlln the preaure adjuatinSi screw locknut 70 to 76 In. tba. torq~. using torque WQnch acYpter. 8acharadl No. 66Â·0148. NOTE: The pressure adju.ting .crew must M kept from tumIng while tightening the ~u1. Rechedl: 01*1ina pressure on the tNt stIInci.

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Section

3052 ENGINE CONTROLS . FUEL LINES AND FUEL TANK

J I Case

A Tenneco Com~n)'

C. E. Div, 9- 66015

..... no ,.. la_,, _

February 1976

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3052-2

THROTTLE ADJUSTMENTS Engine Speeds

Adjust length of throttle rod so throttle lever on Injection pump moves an additional 1/ 16"-1/8" (1.6-3.2 mm) after contacting the low idle stop on the injection pump.

Check to see that the throttle lever on the injection pump moves an additional 1/ 16"-1/8" (1.6-3.2 rrun) after contacting the bigh. Idle stop on the injection pump. Adjust the band throttle stop bolt. Figure I, as requ1red.

Low idle •. , ' . . . . . . • • • . . 725: 25 rpm

(ri mln) High Idle . . . . . . . . . . . , 2250 : 20 rpm

(r/min)

Hand Throttle Adjustment 1.

Engage parking brake and place four

speed transmission In Neutral. 2.

Check low and high. idle speeds using a suitable tacbometer.

Start engine and run at low tdle. Disconnect throttle rod at throttle lever on injection pump.

Hold throttle lever against low idle and bigh idle stops on injecUonpump and note engine speed.

Accelerator Pedal Height l.

Check to see that band throttle linkage is properly adjusted,

Place band throttle in full throttle position. Adjust length. on pedal clevis rod as required to obtain 1/ 16"-1/S" (1.63.2 mm) clearance between the pedal and pedal stop.

If necessary, adjust engine speeds as instructed in Section 3012.

FUEL TANK REMOVAL AND INSTALLATION 1.

Remove engine as Instructed in Section 2050,

Drain the right and left-hand hydraulic reservoirs.

Remove tube between hydraulic 011 filter and reservoir manifold tube.

Remove tube connected to hydraulic filter inlet and filter assembly from the machine.

Remove manifold between reservoirs.

Drain fuel from tank.

Remove fuel fUler cap, f1llerneckgrommet and wire from fuel level sending unl~

Remove nuts and washers from bottom of fuel tank straps.

Lower fuel tank and swing bottom of tank toward the front at the same time to remove the tank.

10. Reverse steps 1 through 9 to install the fuel tank. It is recommended that fuel drained from tank be filtered before it is returned to the tank,

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3052-3

FUEL TANK MOUNTING STRAP REPLACEMENT

A mounting strap can be replaced without removing the fuel tarue 1.

Remove access CQver on top of instrument panel to gain access to the top.

strap nut and washer. 2.

The mounting strap stud goes through the firewall just below flange at top of firewall.

Install top end of mounting strap first. Remove cover over hydraulic reservoir relief valve. The strap can be viewed through this bole to aid in installation. Install '.Io'8.sher and nut on top strap stud.

Install washer and nut on bottom strap stud,

Remove nut and washer from bottom of

strap and remove strap.

Install access covers,

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3052- 4

VlVt ,

•

\. IWftl THROTTl( STOP BOlT

2. rRICTiON OISC 3. TIGHTEN TO HOLD HAND

THROTTLE IN "LACE YET IllVE Sl-lOOTHl y

4. TORQUE CL.AAP B(l.TS TO 13-15 rOOT-POlIIOS (18-20"_) 5. IF ACCELERATOR PEDAl STICKS , tU!!R ICATE ROO A.I\'Il TUBE

111611

Figure 1 - Throttle Linkage -

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3052-514

...• 6

•

. ..;

.-;: ;."

!/ '

I . FUEL RETURN LINE CONNECTED TO ~EAR fUEL lMJECTOR

2. DRAIN YALVE 3. SHUTOFF VALVE

Figure 2 - Fuel Tank and Fuel Lines

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3052-6

••

/ /

IQJIlI (I;l'~

-e

1 I

1 1 1 'I 1

, I

I I

"fJ'~

. • i·

~,1 ~,,,===> - --- - - - - j:

1~1619

Figure 3 - Fuel Lines, FUter to Fuel Injectors

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Section

4002 HYDRAULIC DIAGRAMS. MAINTENANCE. TROUBLE SHOOTING AND PRESSURE CHECKS

J I Case A Tenneco Company

E. Dlv. 9- 6601 5

_ _ WI

u.J..A.

February 1976

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•

. -.4

4002-2

TABLE OF CONTENTS Specifications

Loader HydrauUc Diagram

.....

BacklDe Hydraulic DillFam 3 Point Hitch Hydraulic Diagram

·. .......

. .

.. ,

Hydraulic Reservoir and Filter Service

........'.'

Flushing the Hydrautlc System

. . . . . . . . . .. . . . . . . . .., . ....... .. . .. . ... . .. .. .. , .. .............. .

Problem; Poor Operation of a Single Circuit Only. . . ..

. ......•••.

Probl em: Poor Operation of All Backhoe or Three Point Hitch Circuits, Loader OK . . . . . . . . . . . . . . .. . . . . . . . . . .

. . .. . .. . . . . . . . .

Problem; Poor Operation of All Circuits Trouble Slnotlng Chart Boom Down and Swing Problems

.........., ·

Failure or Poor Opera t ion of Componellts

Control Valve

4002-5 4002 - 6 4002~7

4002-8 4002- 9

Trouble SlDoting

HydrauHc Pump

4002 -4

... . .. . .

..... . . . . . . . . . . .

..... . . . . . . . . . . .. . .. . . . ..

· , ... . . . . . . . · .. . . . . . . . . . . · .. . . . . . . . . . . . . . . . . .. . . . . . . . . .

· . . .. . . . . . · . . . . . . ..... ' .~

Cylinders . . . . ' .. . . . . . . . . . . . 1 ~ . Hoses and Fittings

Testing the Hydl'aullc System With a Flowmeter .•. . • . . . . . • . • • • • . . • . . . .. Test NO.1 - Pump Output

4002-9 4002-12 4002-12 4002-14 4002-14 4002-1-1 4002-14 4002·15 4002-16 4002-17 4002-18 4Cl02- 18

.. . . . . . . . . .. . .... . .

4002-19

Test No.3 - Loader Circuits ......••••.•••••••••••••••• •• •.

4002-22

Test No. 4 - Backhoe Circuits . . . . . . . . . . • .

4002-22

Test No . 2 - Main Relie! Valve . . . . . .

......

. . . . . . . . . . . . . . . . . . 4002-26 Boom Lock Relief Valve Pressure CheCk · . . .. . . . . . . . . . . , . . . . . 4002-29 Loader Main Relief Valve . • • . • . . . . . . . . . . .. . · ... . .. .. . . . . . . ... . . 4002- 29 Pressure Check . . . . . . . . . . . . . .. , . .. . . · . . . . . . . . . . . . . . . . . . 4002-29 Adjustment . . . . . . . . . . . . . . . . . . . . . . .. . 4002- 29 Three Point Hitch Main Relief Valve . . . . . . . ... . . . . . . . . . . . . . . . . .-... . . .. 4002-30 Pressure Check ... . . . . . . . . . . . . . . . . . . .., . . . . . . .. . . .. . . . . . 4002-30 Adjustment 4002- 30 ....... .. .... ... ... ........ . .--........ ... . Pump Protectioo Valve . . . . . . . . .... . . . . . . . . · . . . . . . . . ... . . . . . . 4002-31 Testing Secondary Relie! Valves With a Hand Pump . ·

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•

4002-3

SPECIFICATIONS Pump output Cessna or TRW pumps

.•• . . .. . . .•. .. .. . . 24 U.S. gpm at 2000 rpm at 2000 psi

(91 lfmln at 2000 r/mm at 13 789 kPa) Main relief vaIve setting Oil temperature for test purposes. . . . . . . . . . . . . . . . . . . . . . . .. 120· F (49- C) or loader control valve inlet tube very warm to the touch. Loader control valve .. ~ .. .• .. . • • . . . . . . ... . ... 2300 '" 50 pal at full throttle (15 857 :t. 344 kPa a t full throttle) Three point hitch control valve . . . • . • .. . . • . . . . . .. 1800:t. 50 psi at fuji throttle (12 410 .. 344 kPa at ful l throttle)

Backhoe and stabU1zer control valves

. . . . . . . . None. Circuit pressures controlled by relief valve in loader

cootrol valve. Pump protection valve (three point hitch only machine) . 2600 '" 50 psi at 1100 engine rpm (17 9264 ± 344 kPa at nOO engine r /mln)

Secondary relief valve on temperature for test purposes

Oil temperature- for hand pump should be at room temperature, preferably 70 0 _80. F

Hand pump setting Loader bucket A and B port

(21°~ 26, 7·

C).

Full flow setting

, . , ..... , 2100-2300 psi (14 479-15 857 kPa)

Backhoe bucket and dipper A and B port " , .. . . . . . . . . ...•.• 2400+200 - 50 psi (16 547 +1387 - 344 kPa) Swing A and B port, •.•.... . __• . . . •. 1800 ± 100 psi (12 41 0 ± 689 kPa) Boom A port . . . . • . . • . . . .. , . , •. " . 700 .. 75 psi 1000 a: 75 psi at 10 U.S. r;Pm (4826 ± 517 kPa) (684 '*= 517 kPa at 37.81/mn) Boom B port , ... , ... . • . . . .. : . , 2400 + 200 - 50 psi .' (16 547 "+ 1378 -344 kPa)-Three point h.ltch Hft . .• • -, :"':'•.• .•••.• ,. 1900 pst (13 100 kPa) Boom lockout reltef valve . . . . . . . . . ..•. 3400 ± 100 psi (23 442 ± 688 kPa) Hydraulic all . . . . . . . ... •... •.. . . . . . . .. ':. . . . . . . . . . . • . . . . .. Case TCH Fluid Alternate all ... , . . . . . . , .. , ... , . . . . . . "1, Type C2 transmlssicm fluid such as oJ'" , Tenneco Hytrans Fluid.

'.,. .' A ,

•

,.,.

2, SD or CA engJne all. If lowest ex-

pected temperature is above 32' F (0' C) use SAE lOW. If temperature is below 32' F (0' C) use SAE 5W.

• Hydraulic reservoir and system capacities Reservoir refill, all models . . . . • , . . . . . , . , ... , •.. . 17 U.S. gallons (64 liters} System capacity Loader only. , . . • . • . . . ._...•.• , , .• ' ••. , . 20.5 U.S. gallons (77.5 liters) Loader/bliCkhoe ." ••. . . ,. . . .. . . . . . . . . . . 28. 8 U.S. gallons (109 lIters) Loader/ three point hitch . . .. . . . . . . . . . . . . . , . , 24 U.S. gallals (91 liters) Three point bitch cnIy . . . . .. .• " . . . . . . . . . . . . 19 U.S. gallalS (72 liters) 011 change interval . . . . . . .. ._•.•.• : . • ~. • . . • .. After every 1 000 hours of operation Gil fUter change interval • . . . . . . . " ••••••. ,. Every oU change and whenever filter cOllditlcm light comes 00. Refer to page 4002- 7.

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4002-4

------

I I I

..______~--~ I--------------------

•

~----------~~I ------------------ - R£11.J1tftC aI L SUCTION OIL _ _ PUMP Fl..O'.'i OIL TO/FRO~1 CONTROl.. VALVE ..... A PORTS AND CYLINDERS OI L TO/FROM CONTRal VALVE 8 POOTS AND CYl.. INOERS

1______ - - - - - - - I I I I COMPONENTS 1. 2. 3. 4. 5. 6. 7.

RESERVOIR OIL FILTER HYDRAULIC put~p LOADER CONTROl.. VALVE LIFT CYLINDER BUCKET CYLINDER CLAM CYLI NDER

•

I I I I

L.I__

II I

FRor~

t--------

REA\ MOUNTE!l EQUI PMENT

Figure 1 - Loader Hydraulic Diagram

I I I

-- - -

: I

r~OUJrElJ

TO REAR EQU I PMENT

7515 36

4002-5

DIAGRAM FOR STANDARD BACKHOE IS THE SAME EXCEPT EXTENSION CIRCUIT LEFT OUT.

1II0Tat

Ij --------I

10 L... j -......_ _ _UIiI~W

I I

~- IÂ·I-........- - - . - .

I I

I ----

__ PUMP FLOW. VIA LOADER CONTROL VALVE OIL TO/FROM CONTROL VALVE _ A PORTS ~D CYLINDERS OIL TO/FROM CONTROL VALVE B PORTS AND CYLINDERS - - RETURN OIL-TO RES ERVOIR

L..-_ _ _ _ _......

BACKHOE VALVE SECT IONS

1. 2. 3. 4. 5. 6. 7.

INLET SWING BUCKET DIPPER BOOM EXTENSI ON OUTLET

Figure 2 - Backhoe Hydr aulic Diagram

COMPONENTS

8. 9. 10. 11 . 12. 13. 14 . 15.

BACKHOE VALVE STABILIZER VALVE STABILIZER CY L. SWING CYL . BOOM CY L. DIPPER CYL . EXTENSION CY L. BUCK ET CYL .

1515]7

4002-6

J I I

i-----O' -_._------~-------I..-.I I

I I

â&#x20AC;¢

; , I

I 1_-

__ - , I

I I I I I I

I - - - T - - - - -- - IL ____

--_II

r======:~~~~rn 8

----

7 -

COMPONENTS

SUCTI OH OIL 1. 2.

RETURN OI L _ _ JlUM.P FLOW

- -

OIL TO/FROO CONTROL VALVE A PORT .~ O CYLINDER ..... OI L TO/F RO~ CONJROL VAL VE B PORT AHO CYLINDER

3. 4.

5. 6. 7.

RESE VOIR FI LTER PUfolP HITCH CONTROL VALVE LIFT CYL INDER TILT CYLI NDER PITCH CYL HIOE R REL IEF VALVE

Flgure 3 - 3 Point Hitch Hydraulic DIagram

V ALVE SECTIONS

9. 10. 11. 12.

IHLET/OUlLET IMPLEMENT PITCH

TILT

LIFT 14 . END COVER

13.

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4002-7

HYDRAUUC RESERVOIR AND FILTER SERVICE

Oil Level Check

should be cleaned wbenever the bydraullc oil is changed.

The oil level must be checked when the

oll Is cold (prevailing temperature, indoors or outside). 1.

Park machine on a level surface.

Place backhoe. U 80 equipped. In the transport position and the loader bucket rolled back at groond level.

A sight level gauge is located in the left-band reservoir. If oil is Dot viaihle through the glass. remove plug and add oil as required. Refer to page 4002 - 3 for specified oll.

Oil Drain The reservoir oil must be drained after evory 1000 hours of operation.

If time allows, warm oll to operating temperahlre before draining.

Park machine en a level surface with backhoe, if so equIpped. in the transport

Access to the breather is through the bold on top of the frame. Remove the breather, clean in cleaning solvent and dry with moisture free compresSed air b.efore installing.

Oil Fitter The 011 filter must be changed after the first 20 bours of operatioo, whenever the hydraulIc oU is changed or when the filter warning I1ght 00 the inl!trument panel stays

on.

To check filter coodiUoo, warm 011 to operatlng temperature and run engine at full throttle and observ_ruter warning light. U light comes 00 and 'Ways 00, the filter must be changed. The warning l1ght may come en when the 011 Is cold; this 15 normal. The ruter is located under the hood in front of the fuel tank 00 the right-hand side of the machlne.

To change the filter:

position and the loader bucket rolled all

the way back at ground level. 3. 4.

â&#x20AC;˘

Have Ql band drain pan and containers that will hold 1 7 U,S. gallons (64 liters).

Remove fill and drain plugs from leftband reservoir and drain oll . Then remove drain plug from rig h.t_hand reservolr and drain oil,

Install drain plugs and fill reservoir with .11 U.S. gallons (64 Uten) of CUf;!; TCH F1u1d. Add oil as required to fill rf;!;servoir to the proper level.

Re. .rvoir Breather A breather is located CD the inner panel of the right-hand reservoir. Tbf;!; breather

I..ooS81 reservoir fIll plug to relieve pressure in reservoir .

Unscrew filter houSing from filter bead. Tbe filter may be torqued up to 90 footpounds (122 N m).

Remove filter and discard. Remove housing ~ring and inspect for damage that would result in leakage and replace as requIred.

Install filter (D filter head. Gasket 00 lD. must be 00 top,

Install ~r1ng in iToove in filter housing. Lubricate ~ring with hydraulic 011 and screw bousing into head. Torque housing up to 90 foot-pounds (122 N m).

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4002-8 "

FLUSHING THE HYDRAULIC SYSTEM The entire hydraulIc system may require flushing if a system component Called due to contam1nated oll. Whether to flush the system Is dependent on an oil sample. page 4002-13, " and your personal judgment. Hthepump!a.iled. also refer to Identifying Causes of Pump Failure In Section 4005.

Start the engine and flu sh each circuit by moving each control lever in both directions untll the lines are flushed with new oil. This flushes the lines and valves from the pump to the cylinders. .

Connect lines to the CLOOED end of all cylinders except the Swing cylinders, Leave the rod end of the cylinders disconnected and with the engine running at 1/ 4 throttle. activate each circuit slowly until the cylinders bottom out. Newall will be put in the c losed end of the cylinders and the cCXltaminated oU forced out of the rod end.

Flushing Procedure Retract all cylinder rods and swing backhoe all the way to the right.

U retractlllg the cyli..ndcr rods C:luses the attachment to be . . ralse(t, Liock the attachment l/l piiJ,ce WARNING:

bcfoz"e J)!'oceeding to the nt'xt step" 39-4 2,

Drain the hydraulic reservoir and remove and discard the hydraulic fllter(s).

Install new filter and fill reservoir with new Case TCH fluid.

1'>...

Connect lines to rod "end of all cylinders except swing cylinder and check reservoir all level.

CQlIlect hoses to the

rod end of the left swing cylinder and closed end of the right swing cylinder. Slowly swing backhoe all the way to the left. Then connect remaining hoses to both swing " cylinders.

Operate ail cylinders alternately for 15 minutes with engine running at full throttle.

WARNING:Before completdlg ',kp;;, attachments J.ll blocked

place

;)9-5

Dlscmnect all lines to cylinders at the cylinder. NOT_: Check reservoir oll level frequenUy while performing steps 6 and 7 to prevent pump damage.

l/l

. . make sure all III

If attachment LS raIsed . pl.u.'c before completlllg step :19-6

WARNING:

. . block ';'.

10, Change the hydraulic filter. Check reservoir oil level and add as required.

â&#x20AC;˘

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4002-9

TROUBLE SHOOTING Problem: Poor Operation of a Single Circuit Only li only CIle circuit 1s performing poorly the problem 1s in tbat circuit. Possible causes are worn cylinder packing, secoodary relIef valve (if used) settlng to low or leaking, leaking load check valve or worn spool or spool oore. DETAD..ED INSTRUCTIONS

CHECK

Check cylinder packing.

Loader lift cylinder.

Raise loader arm to full height and block in place. DiscOMect tube at rod end of each cyl inder and loosen clamp and slide tube away from fitting. StArt engine and run at full throttle. Move control1ever to the Raise position, hold in

place and check for leakage at each cylinder. Any leakage indicates WQrn packing and repair of that cylinder. Checking leakage in the opposlte direction cannot be done unless the pistons are prevented from bottoming in the cylinder. In almost all cases, leakage in one direction will result in leakage In the opposite direction. b.

Loader bucket cylinder.

Cla.m bucket cylinder.

Backhoe boom cylinder.

Âˇb.

Raise loader arm. completely rollback bucket and rest bucket on the floor and block in place. Dlsconnect hose at rod end of each cylinder. . Start engine and run at full throttle. Move con. irol lever to the Rollback position. bold to place and check (or leakage. Any leakage Indicates worn'"Packing and repair of that cylinder. However, leakage in one direction usually results in the opposite direction.

. ..

Close clam. Disconnect Mse to rod end of each Âˇcylinder. Start engine and run at full throttle . Hold control lever in Close position and cbeck - lOr leakage. Any leakage indicates worn packing and repair of that cylinder. Chocking leakage in . the opposite direction cannot be done unless the pistons are prevented from bottoming in the cylinders. Usually, leakage in one direction n:l:Iults in leakage in the oppoolte dirootion . . d. Place ba.ckooe boom in the transport position. Disconnect rubes at rod end of each cylinder. . Loosen tube clamp and sl1de tube II.WII.Y from -fitting. Start engine and run at full throttie. Hold control lever in the Lower poSition and - _., . check. for leakage. Any leakage indicates worn packing and repair of that cylinder. Leakage in one direction usually results in leakage in the opposite direction.

..,-;

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4002-10

DETAILED INSTRUCTIONS

CHECK

Backooe dipper cylinder.

Backhoe bucket cylinder.

Completely extend the bucket cylinder. Disconnect tube at rod end of bucket cylinder. Loosen tube clamp and slide tute away from fitting. Start engine and run at full throttle. Hold control lever in the Load positton and check for leakage. Any leakage indicates worn packing and cylinder repair. Leakage in the opposite direction can be checked by disconnecting hose to closed end of the cylinder and holding the control lever in the Dump poSition. However. leakage in one direction usually results in leakage in the opposite direction.

Pin swing tower in center position. Disconnect hose to closed end of left swing cylinder. start engine and run at full throtUe. Actuate swing control to swing to the left and bold. Any leakage indicates worn cylinder packing and repair of that cylinder. To Check leakage In the opposite direction actuate swing control to swing to the right. However. leakage in one direction usually results in leakage in the opposite direction. Block up -rear of machine so stabilizer can be completely lowered without touching the floor. Dlsoormect line to rod end of cylinder. Start engine and run at full throttle. Hold control lever in the Lower position and check for leakage. Any leakage indicates worn packing and repair of that cylinder .

â&#x20AC;˘

-J>

Backooe swing cylinders.

Backhoe stabilizer cylinder.

Backhoe extension cylinder.

With the boom in the tr8I}sport position, complete1y extend the dipper cylinder. Disconnect tube at rod end of dipper cylinder. Loosen tube clamp arld slide tube away from fitting. Start engine and run at full throttle. Hold control lever in the In position and check for leakage. Ally leakage indicates worn packing and cylinder repair. Checking leakage in the opposite direction cannot be done unless the piston is prevented from bottoming in the cylinder. However. leakage in one direction usually results in leakage in the opposite direction.

.',

,,2;i.;.

Completely extend dipper extension and rest backhoe bucket on the floor. The Mse to rod end of the extension cylinder is connected to tube on _ the top left side of the dipper; disconnect rose at this connection. Start engine .and run at ,full throttle. Hold control "lever in the Out position and ,check for leakage. Any leakage indicates worn packing and cylinder repair.

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•

4002-11.

CHECK

DETAn..ED INSTRUCTDNS

Three point bitch

cylinders.

Completely extend all cylinders and block hitch and attachment in place. Disconnect bose to rod

ead of cyliDders as required, Start engine and run at full throttle. Move control lever to exl:ebd the cylinder, bold and check for leakage. Any leakage indicates 'M)m packing ADd repa.lr

ollhat cylinder. 2.

It DO leakage was found. or cylinder was repaired

The following circuita oontain secondary relle! valves: loader bucket, backhoe boom, dipper, bucket and swing, aDd three point hitch lift. Refer to

and circuit still operates poorly. cbeck secondary

Testing Secondary ReUe! Valves With a Hand Pump in this section and check pressure setting.

relief valve if in the c1rcuit.

If the complalnt W8JI that the load drops in the op-

Load c'heck valves are used in all the valves OIl this machine. 'The load check ValV88 molt Hkely to cause problems 'are in the backhoe bucket B port, boom B

posite direction. the problem is a leaking load

port. dipper A port. loader bucket A port and three point hitch l ift which is located 'm the 11ft spool. Remove control valve br inspectIon and

check valve.

r .......

If checks and repairs to t.h1a point have not corrooted the problem, spool leakage is probably the cause.

Remove OOIltrol valve br dlsassembly and inspection. U a worn spool or spool bore 11 the problem, the complete valve or valve section must be replaced.

.'a 11 •.

....,

---.. AfI:

h· ....

.., -.......'•

•

t ,

••

•

...... 'r

• ~-

•

...,.,

•,

... ~

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â&#x20AC;˘

Problem: Poor Operation of All Backhoe or Three point Hitch Circuits, Loader OK REMEDY

POssmLE CAUSE

Defective Q-ring on p:>wer beyond fitting in loader

Disconnect tube connected to power beyond fftting. The fitting is located on the outl_t side of the loader control valve. Remove O-ring on inner end of fitting and cbeck for damage.

oontrol valve. 2.

Damaged or plugged quick disconnect couplings.

Remove all couplings. male and female, and check for foreign material and properly operating valves, Repair or replace parts as required.

Dirt or worn or damaged parts in regeneration circuit in

Refer to Section 4107 and remove. disassemble. inspect and assemble the inlet and outlet sec-

backhoe control valve.

tion as .instructed.

Backhoe valve inlet or outlet section cracked internally.

Same as above.

Three point hitch valve inlet section cracked internally.

Refer to Section 4034 and remove, dIsassemble, inspect and assemble control valve as instruc-

ted. 6.

Dirt orwom parts in three

Same as above.

point hitch valve inlet section.

Orifice plate or pilot passage in three point hitch control valve plugged.

Problem:

Poor Operation of All Circuits

When all circuits perform unsatisfactorily, a worn pump is the most commen cause. However. before removing the pump, make the checks listed below.

CHECK

DETAll..ED INS.TRUCTIONS

Oil level.

Check the hydraulic 011 level and add all as required. See page 4002-7.

2. Oil level.

Change the hydraulic all filter. See page 4002-7.

3. Check pump intake line.

Check the intake Une between the pump and the hydrauliC reservoir for a loose connecthn, damaged or loose fittings and lines.

4. Check setting of main relief valve.

See page 4002-29 in this secticn for main reUef checks and adjustments.

5. Check hydraulic stall

Refer to Sectloo 2050 for instructiens.

,peed.

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•

4002-13

CHECK

DETAU...ED INSTRUCTIONS

6, Check for cootaminated

oll,

Operate the engine {or a short period of time to circulate the bydraulic oU. Take an oil sample and look: for the following 8i@pS:

Feel the aU with your fingers. See tf the oil is gTttty or contains any particles large enough to be felt.

, .'¥"

MUky color oil is a sign of water in the oil.

Foam is a sign that air is entering the system.

The system bas overheated severely if the oil Ie dark, thiok or smelis scorohed.

If the oU Is found to be cootaminated. the oil muet be replaced and the ruter changed. See Flushing the Rydr:aulic System on page 4002-8, After replacing the all, check pump output with a flowmeter to determme bow much damage. if any. the pump bas sustained from the bad oil.

7. Check pump output with flowmeter.

Test procedure is in this sectioo 00 page 4002-18. U pump output is not at least 80% of the specifioaUoo. repair or replace the pump.

. '

. , . •

'" •

•

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4002-14

Trouble Shooting Chart Boom Down and Swing Problems SYMPTON

POSSIBLE CAUSE

REMEDY

Boom drops (lower) too fast

Restrictor in B port of boom section missing or lmproperly installed.

Lower backhoe bucket to the floor. Disconnect mae at B port of boom section and remove fitting. Check to see that restrlctor is installed properly; large end toward valve section.

Boom coasts with spool in Neutral

Secondary relief valve pressure setting too low or foreign material holding poppet off its seat.

Check pressure setting with hand pump as instructed in this section, or remove valve, diBassemble and check for fore1gn material.

Backhoe swing stops with jarring impact

Restrictor in closed end of either swing cylinder missing or improperly installed.

Disconnect hose at closed end of cylinder and remove fitting. Check to see that restrictor is installed properly; sm'lll end toward cylinder.

Restrictor oole diameter: with Extendaboe .125" (3.17 mm) without Extendaboe .156" (3.96 mm) . ...

Same as Boom coasts with spool in Neutral. See above.

Failure or Poor Operation of Components HYDRAULIC PUMP SYMPTOM

POSSIBLE CAUSE

REMEDY

Pump is noisy

Loose mounting bolts.

Torque to specifications.

Loose pump tie bolts.

Torque to specifications.

Worn or damaged bearings or gears.

Remove pump and repair.

Air leak in suction line.

Repair as requLred.

Worn or damaged pump. Also see JdenWYing Causea of Pump Failure, Section 4005.

Remove pump from machine. Repair or replace pump as required. H oU Is contaminated, flush the complete system as instructed on page 4002-8.

Flowmeter test indicates low pump output

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â&#x20AC;˘

4002-15

SYMPTOM

POSSmLE CAUSE

:REMEDY

Flowmeter test in-

Restriction or air leak between reservoir and pump Inlet.

Repair as requlred.

Use of Improper oU.

Use oU apecllied on page 4002-3.

dieatea low pump output (Cont'd)

External ollleakage

Remove pump and replace

Worn seal or pump aba.ft..

seal. Chec:k .balt at sealing IIllrCace j)r damage.

Unplug passage between seal

Shaft seal "blown" out.

and reUef valve In troot cover.

Check parts for damage. Pump tie bolt. loose.

Torque to specification.

Defective pump section

Disassemble pump and replace the D-ring.

O-rmg. Low oll supply

Low oll level.

FUl reservoir to proper level with oll .pecilied OD page (002-3,

CONTROL VALVE SYMPTOM

POSSmLE CAUSE

REMEDY

Spool leaks oil

Defective spool seal.

Replace spool seal.

Spool doea Dot l' eturn to neu tr a1

CSlteriog spring brokflD.

Replace sprmg.

Bent spool

Replaoe oontrol valve.

Damaged spool bore.

Replace control valve. LooSeD .alve moW'ltlng bllts

WIU"J*l vahe body.

and shim at low spot.

Sluggisb operation

to specU1catJon.

Tie rods over tigbtmed.

Torque

Incorrect main relief .,aha setting.

Check and adjust pressure setUng as m.tructed In this lIecUon.

Main relief valve leak.lng internally.

Replace relief valve.

Excessive clearance betweeD spool and spool bore.

Replace control nlva or valve sectlon.

Spool not properly positlo,ed.

Measure spool travel and adjust control linkage.

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4002-16

SYMPTOM

POSSmLE CAUSE

REMEDY

Spool will Dot stay in detent position

Worn or m!ssing detEmt parts.

and repair as required.

Load drops as contro lever is moved to power position

Leaking load check valve.

Di.su8emble detent mechD.niBm Remove oontrol valve and inspect load check valve parts including poppet seat. Also refer to page 4002-11.

CYLINDERS

SYMPTOM

POSSffiLE CAUSE

REMEDY

Sluggisb or no movement

Worn piston packing.

Check cylinder packing Instructed under Poor Operation of a Single Circuit, page 4002-9.

Loose piston boll

Remove cylinder and repair as required.

Hoses not properly oonneeted.

Refer to bydrauUc diagrams and check connections agalnst dlagram. Reconnect hoses as required.

Failure to lubricate pivot-

Lubricate pivot points daily or more often if operating .In severe conditions.

Excessive cylinder buShing wear Excessive cylinder packIng wear

Bent piston rod

points as specified.

Contaminated oll.

Flush the complete hydraulic system as instructed on page 4002-7,

Incorrect main relief valve pressure setting.

Check and adjust pressure setting as instructed In this section.

Failure to lubr tcate pivot pins as spec1f1ed.

Lubricate l1tt1ngs da.1ly or more often if operating In severe conditions.

Incorrect main relief valve pressure setting.

Check and adjust pressure setting as instructed in this aection.

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4002-17

HOSES AND FfTTlNGS SYMPTOM

POSSIBLE CAUSE

R ,;MEDY

Hose cover

Hose twisted.

Install bose properly; connect hose at swivel fitting last !Uld make sure hose does not twist

separated from wire braid

when fitting is tightened. Fitting pulled from

Install bose properly; connect rose at swivel fitting last and

Hose twisted.

hose or broken hose

make sure bose does not twist

when fitting 1s tightened. Incorrect main relief valve pressure setting. Damaged threads

Check aJ'ld adjust pressure setting ~ instructed in this section,

Torque to specifications. Section 1051.

Overtorqued.

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•

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11'~

...,

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4002-18

TESTING THE HYDRAULIC SYSTEM WITH A FLOWMETER Hydraulic troubles in this and other Case machines can be quickly and positively diagnosed with tbe aid of a flowmeter. ThIs prevents trial-and-error replacement of parts. The flowmeter is portable and can be used in the shop or easily transported to the field for on-the-spot trouble shooting.

Two Flowmeters Available Two flowmeters are offered througb the Case Service Tool Program. Refer to the Case Service Tool Catalog, SPS 179- Revised.

Figure 5 - 100 gpm Flowmeter Test procedure coosists of:

r-... ... â&#x20AC;˘

First. learnJng how mucb oil the pump delivers to the system at no load.

Then, by operating the pump at the same speed but against a pressure near the setting of the relief valve, finding out row much oll is unavailable for w-ork because it Is:

â&#x20AC;˘

Figure 4 - 60 gpm Flowmeter a.

Not delivered by the pump. due to an air leak or restriction in the 8uCtiOO 1in e.

Not delivered by the pump. due to internal damage or wea.r in the pump.

Description of Test Tbe flowmeter simulates the load CCIlditions met during operation of the loader and backhoe and measures the temperature. volume, and pressure of the oU passing through the flowmeter.

By interpreting these measurements as described on the following pages, pump, valve, and cylinder faults can be Identified.

H the pump output is within specificatioos, it can be assumed that the problem is caused by leakage in the cootrol valve or

cylinders, or both.

Test No.1 - Pump Output A cbeck sbeet will be found 00 page 4002-24 that can be copied 00 any office copier. NO,..:

Rest loader bucket OIl the floor and place backhoe in the transport position. If

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4002-19

equipped with three point hitch, lower hitch attachment to the floor. 2.

Refer to Figure 6, Disconnect control valve inle t hose from tee fitting and install plug in hose. Then remove cap from end of tee and reinstall on top. Connect flowmet er inlet hose to this tee.

Remove cap from tee fItting in the centrol valve outlet and cooneet flowmeter oullet hose to this tee.

Loss of outpJ.t at 2000 psi (13 789 kPa) indicates pump wear or damage. Divide the flow reading obtained at this pressure by the flow reading obtained at 0 pst (0 kPa) todeterminepu.mpefficiEllcy, The point at which a pump should be repaired or replaced is a matter of judgement; however, if Punt:' efficiency is 80% or less, aervicing the pump 18 recommended.

The flow readlngs at 600 and 1800 psi (4136 and 12 410 kPa) have no bearing on pu.mp ccoditiCll. These flow readings will be used for comparisco purposes in Test No, 3 and 4.

Set the flowmeter volume control to handle 30 U.S. gpm (113 l/mln) and open the load valve, In this hookup there is no relief Therefore. the flowmeter load valve must be partially OpES!. at all times during this test. MOT.:

Test No. 2 - Main Relief Valve

valve.

Start engine and run at low idle. IT oil temperature is less than 120Âˇ F (49- C). run englne at 1/2 to 3/4 throttle and close load valve until pressure gauge indicates about 1000 psi (6894 kPa). Hold until oU temperature is 8S specified.

Âˇ ~6.

Open the load valve completely. Run engine at 2000 rpm (r/min) and record flowmeter r e ading.

Witb engine running at 2000 rpm (r/min) gradually close flowmeter load valve and record flow reading at600psi (4136kPa). 1000 psi (6894 kPa). 1800 psi (12 410 kPa) and 2000 psi (13 789 kPa). As pressure increases it wUl be necessary to adjust engine speed.

Refer to Figure 7. Remove cap on top of tee in the inlet lineandC(l(J.nectccr.trol valve inlet bose to tee. The flowmeter connect.ions remain the same.

Open flowmeter load valve and start engine.

With the engine running at full throttle. move the bucket cootrol lever to Rollback ...and hold lever in this poSition. Gradually close the flowmeter load valvei allow the bucket to roll back completely. Continue to hold the lever In Rollback and close the load valve. Watch the flow gauge; the volume will slowly drop as load increases due to engine rpm loss. However at the point of the main relief crack the flowmeter will take a more rapid dip; bold this point on load valve and flow gauge and read pr es sw-e gauge for crack pressure of main reHef. This should be'110 more than 10% below the full open reading.

Continue to close the load valve. When the volume drops to zero or very near zero, read the pressure gauge and record the reading. This is the setting of the main relief valve. (.pen flowmeter load valve and stop the englne.

Interpreting Test Results 1.

()

If output at 0 psi (0 kPa) is less than the rated pump output it Is an indication of a restricticr. or air leak between the pump and reservoir. If output met or exceeded the rated output itdoesnotmean the pump is good; it only Indicates no problems between the reservoir and p.1mp. NOTE: With the load valve completely open it is possible to exceed the output Wlder specifications.

Interpreting Test Results 1.

H the reading obta.iDed in step 4 is not as specified. adjust the relief valve as instructed in this section.

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4002-20

,, ,!

FLO\t£TfR

REF.

PART NO.

1\21574

2. 3.

218·466 220·206 218·777

••

NO. REQ'O

DESCRIPTION 3/4" 1.0. BULK lONG ENOUGH TO USE FLOWMETER IN OPERATOR'S SEAT 3/4" HPT TO 1·1/16"·12 JIC ADAPTER 1·1/16 "-12 JIC S1oI!VEL F1TTIII6 ··PlUG

,"OTl!, COWlECTlfmS AT FL~'!1ETER OPTIONAl. DEPEJfOltIG 011 HOSES ALREAOY A.VAILABLE.

•1 751539

Figure 6 - Flowmeter Hookup for Pump Test

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4002-21

.! , j

REF.

,. 2.

.~O .

DESCRIPTIOI'!

PART NO •

MO' D

314" I D

A21574

(lPERATOA.~ ,.,,,,. , "C"""," ~ n~"

216-4 66 220 - Zln

USE /lOS( L()tG 3/4 " MPT TO 1 1M

J>'

Ta:COIIMECTIOI'(S AT Fl

OIot!£TEl

vn<rr .... 11lIW.

SWIVEl. F1TT IIIG ER DEPEnD 1M' ON HOSES ALRtADV

4 A~A l lABtE.

FIgure 7 - Fl owmeter Hoolcup for Circuit T ost

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4002-22 2.

If the pressure setting was as specified and the crack pressure was 2000 psi (13 789 kPa) or lower, disassemble the relief valve and check for worn parts. Replace parts as required and recheck crack pressure of the relief valve.

packing leakage In one or both cylinders or secondary relief problems. Reier to Poor Operation of a Single Circuit, 4.

If the bucket circuits had eIl.elowreading and the other reading was close to pump output at the same pressure. the most likely cause 1s an improperly adjusted or leaklng secell.rlal'Y relief valve for the circuit with the low reading or piston packing if loss was in Rollback. Remove the relief valve, disassemble and check for worn parts. Install relief valve and check pressure setting as instructed in this section.

If checks and/or repairs to this point have failed to correct the problem or reveal source of problem. a badly worn spool and/or spool bore is the probable cause. Remove cootrol valve, disassemble and check for excessive wear,

Test No.3 - Loader Circuits 1.

Connect :flowmeter into circuit as illustrated in Fik.a"e 7 (same as Test No.2).

With the engine running at 2000 rpm (r /min) move the control lever to the Rollback position. Loader arm must be all the way down so antirollback linkage wUl allow control spool to be fully stroked, Hold control lever in place and close flowmeter load valve until pressure gauge indtcates 1800 pst (12 410 kPa). Adjust throttle setting 88 required to maintain the specIfIed engine speed. When the piston rod stops moving observe the flow gauge and record the reading. Raise the loader arm high enough to completely dump the bucket (the flowmeter load valve must be partially closed or cylinders w1ll not move) and repeat this step holding the control lever in the Du~ position.

Te.t No.4 - Backhoe Circuits 1.

Connect flowmeter into circuit as illustrated in Figure 7 (same as Test No.2).

With the engine nmning at 2000 rpm (r /min) move the boom control lever to the Up poSition. Hold control lever

Test the loader raise circuit and the clam close circuit in the same manner.

in place and close flowmeter load valve. When the piston rod stops moving, Close load valve until pressure gauge iodicates 1800 psi (12 410 kPa) and adjust throtae as required to maintain the specified engine speed, TbeSl observe flow gauge: and record the reading. Repeat this test with the control lever in the Down 'POsiton with the flowmeter load valve adjusted to 600 pst

Interpreting Test Results 1.

If the flow reading for a given circuit was close to the reading obtained in the pump test at the same pressure, the circuit is good.

If the flow reading was low for aU cylinders it indicates leakage before the oil reaches the cylinders. Leakage could be past the O-ring ell. the main relIef valve cartridge or seatsleeve, orthrougb the main relief valve itself because the circuit test was performed at a pressure higher than the crack pressure reading obtained in Test No, 2.

(

(4136 kPa).

If the flow readings for the bucket circuits were both low. it indicates piston

Check the bucket Circuits with the control lever in the Load and Dump positions at 1800 psi (12 410 .kPa) with the engine running at 2000 rpm (r/mtn). If test results in roth positions were not the same or very close to the pump output at the same pressure, refer to step 3 under Interpreting Test Results. At least one bucket circuit D:J.lst be in good condition to efiecUvely cbeck the stabilizer circuits.

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4002-23 4.

Check both stabilizer cylinders in the Lower position at 1800 pst (12 410 kPa) with the engine running at 2000 rpm (r/mm). When the stabilizer piston rod stops moVlng. move tile bucket control lever to the Load or Dump Position, whichever circuit is good. Hold both levers in place for remainder of this test. The spools in the stabilizer control valve are a random fit in the spool bores which results in bigher spool leakage than in valves with select fit spools. Wben a spool is actuated oil leaks past the spool to the open center passage. Therefore, the reason for actuating the oocket spool is to stop the flow of oil through the open center passage. This exces s leakage could be interpreted as cylinder leakage if the oocket spool was not actuated. When the piston rod is completely retracted. packing leakage is difficult to detect because the piJIton is seated against the closed end of the cylinder.

control valve. Leakage could !!lso bt;l through the main relief valve itself because the circuit test was performed at a pressure higher than the crack pressure reading obtained in Teat No.2. 3.

If the bucket or swing circuits had one low reading and the other was close to pump output at the same pressure. the most likely cause is an improperly adjusted or leaking secoodary relief valve for the circuit with the low reading or piston packing if the cylinder rod was extended. Remove tilt:l relief vHlve. disassemble and check for worn parts. install relief valve and cbeck pressure setting as instructed in this sectlon.

If the flow reading for the boom Up and Down circuits were lower than pump output at the same pressure. the cause could be leaking piston packing or an improperly adjusted or leaking secondary relief valve. Check for leaking cylinder packing as instructed under Poor Operatioo of a Single Circuit. The boom down relief valve (A port) was checked in step 7. Check the relief valve at the B port as instructed in the sectioo.

11 the flow reading for tho dipper In circuit was low the probable cause is leaking piston packing. Checil: cylinder packing as instructed under Poor Operation of a Single Circuit. If piston packing is good. check pressure setting of II. secondary rel1ef val ve for this circuit as instructed in this section.

If the flow reading for the dipper Out circuit was low the probable cause is ar. improperly adjusted or leaking relief valve. Check setting of reUef valve

Check the dipper and swing circuits In both directions at 1800 psi (12 410 kPa) with the engine rwming at 2000 rpm (r /mm). With

the

engine running at 800 rpm

(r/min) bold the boom control lever in the Down }Xlsiton and close the flowmeter

load valve. When the flow reading drops to zero or v~ry clol!le to zero. observe the pressure gauge and record the reading. This is the setting of the secondary relief valve at the A port of the boom section.

Interpreting Test Results 1.

If the flow readlng for a given ctrcutt was close to the reading obtained in the pump test at the same pressure, the circuit is good.

Ii the flow readlngwas low for all circuits it Jndicates leakage before the aU reaches the cylinders. Leakage could be past the O-ring on the main reliefvalvecartridge or seat sleeve (this should have been discovered in Test No. 3) or the O-ring on the power beYOlld fitting In the loader

<18

ift.etruated

~CIn.

RlstOtl

packing leakage w1th the plstoo rod completely retracted is difficult to prove because the piston is seated agaln!!t the closed end of the cylinder. 7.

If checks and/or repairs to this point have failed to correct the problem or reveal souroe of problem, a bac1ly WOrD spool and/or spool bore is the probable cause. Remove control valve, disassemble and check for excessive wear.

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4002-24

U.S. MEASURE FLOWMETER CHECK SHEET -

"""" ..,..

Dale-

SIOC

Serial No.

Pump Efficiency Teat:

Hou~.

T.mpe~l.tI.iMI:

.,,..

,•

GPM at

...

OPM~

, ,,..

OPM at Cl'1eUlcllIPC)'J (dl9'lcie by .J •

Star! Test

GPM at

OPU at

I.' "" 2000

jM;1 at jM;1 a'

pli at

MaiD ReUel, cuek poilU

lett.ll!, LOADER CIRCUITS

.... ...... ..

GPM It

]800

pal at

Clo..,

OPM It

",.

pilat

GPMat OFM al

, ,

OP."

",.

GPMat

"00

0..

R. H. StabUlzer, RW'

"""', L. H. StabUlur,

I.'

OPMIt

"00

QPM

,aoo

GPMIt

1800

OPM ..

QPMd

1.0_,

OPAl

Loft BIlCi:et. Load

""'" Czow, ..

0."

.....

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Low Pr-.aure 5e(x)acl&ry

,"...

1\1.1..

Swln,. Right.

......

QPMIt

18"

OP'" It

1800

GPMa'

1800

OPMa'

"" R.Uaf Vain (now, 5ettlrJp:

Boom, Dowa

,.,

.... "

RPM

Cll.llJ, 0pIm

ElcIIlP<iaMe ..

''''

RPM

>'ill

OPM U

BACKHOE CIRCUITS

RPM

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utt.

'''' ,,..

RPM

OF"'a,

OPMlt

o.",

RPM

'UU

Rallo ..

OPMat

psi at

pilat

"00

,,..

RPM RPM

''''

RPM

psi at

:WOO

RPM

''''

RPM

"00 "00

RPM

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RPM

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RPM

, '''' ''''

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pal at

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RPM RPM

pat It

RPM

pilI.'

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BIIcket, RollbAck

, .. ish T"t

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Circuit L88kage, ''Tee'' T..t:

•

saoc

RPM

RPM RPM RPM RPM

"M "M RPM RPM

800.. , RPM

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4002-25

METRIC MEASURE FLOWMETER CHECK SHEET

..,,"

. S80C

D.,

O ..... e~ SBOC

Hou~s

Serial No.

Pump Efficiency Test :

Temperltu~~:

IImln at

~13~

I/mln Itt Il mln al

r= (divIde by ' j

51&rt Tesl

I/min KI

kP~

kP .. at lP.

12 '4.10

.Pa Itl

13 759

tPa al

('ieme;"''')'1

•

I/mln at

f'lnt,h Test

rlm:n

20~~

r/ mto

"" ""

~ h'''11

ri m;"

·c

. / min

Circuit leakage. ' Tee" Teat: Main

R~IIe!. C~""k

polnl

setting

kPa KI

~' u!l

r/"'ln

kPa at

'm'

r / m1ll

LOADER CIRCUITS l / mVl ilt

12 4J0

kPa It

'''0

r/ mtzl

I/mlll 111

12 -tI0

kPa at

2000

r/mln

l/mln at

12 flO

ItPa at

rll.n"

11m;"

12 410

kPa a t

"" 2000

r/mln

IImln at

12 flO

kPa at

r / on.in

I/mlll at

12 "·4 10

kP. at

"" 2000

~/mln

I/min al

12 -tI0

kP. at

2000

~/mln

l/min at

124JO

ltV, at

r / mln

RaLae

' /mln ' at

12 flO

kPa at

20"

~/mln

"'-,

I/mln al

12 -tI0

ItPa a t

2000

r/mln

IImln at

12 flO

kPa a t

'''0

r / mln

Ilmln al

12 <u0

kPa at

1000

r/mln

I/mln Ilt

12 UO

ItPa at

'''0

'im'"

I/ mln at

124.10

kPa at

20"

r/mln

llmln at

12 'lIO

kPa at

'''0

r/mln

""""

lImlrt at

UUO

,~u

r / mb>

lImln

124).0

k1>a at

"" 20"

D,"

1/mln at

12 -00

kPa a '

I/mln 111

12 flO

kPa at

l/mlrt .Ill

u'"

kPa al

Sucbt. RoUbAl::t

""""

Lift. Rdl'

Lo .. e~

Cl ..... Open Cl~

BACKHOE CIRCUITS f,xt",daboe ..

R. H. StabUmr.

L. H. Slabil!ur. Ralae ",-,

...1.0'"

Swln,. Right

Bucket.

Crowd. In

Boata. Up

Low Prenure Sec<>adary R ellet Vlllve (Flow' Settings:

Boom. Oown

........

20" 20" 20"

rlmln

....

r/miD

r f lllin

800••. r / min

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4002-26

TESTING SECONDARY RELIEF VALVES WITH A HAND PUMP b.

General The following circuits are protected by secCIldary relief valves: loader bucket, boom, dipper, swing and backhoe bucket. The pressure setting of these relief valves can be checked 00. or off the machine with the hand pump set up as Ulustrated in Figure 8 and using the additional parts illustrated in Figures 9 and 10 as required.

When checking swing relief valves, band pump must be connected to tube to the swing secticn.

Refer to Figure 9 for the n~essary parts and coonect band pump to line to control valve. Do not tighten connecticn at this time. The hand pump must be operated against

a solid column of oU. Operate hand pump The hoses and hose fittings in Figure 8 are listed in the Flexible Hose Lines and Reusable Fittings catalog SPS 124. The remaining parts can be ordered in the usual manner. The -fittings illustrated in Figures 9 and 10 are available in a complete hand pump fittings and gauge kit from the Nuday Co. Refer to Service Tool Catalog SPS Âˇ179-Revised for more information and mailing address. The pressure setting for each _relief valve is listed on page 4002-3. The origtnal relief valves in the Case backhoe control valve have anominal pressure setting stamped in the top of the valve cartridge. DO NOT use this figure when checking or setting a relief valve; use the pressure settings 11sted 00. page 4002-3.

to bleed air from line and tighten bose connection. 6.

Actuate hand pump to build up pressure unUl the relief valve opens. Make several checks to obtain an accurate check.

Compare test reading with specified setting on page 4002-3 and adjust as required.

Checking Pre â&#x20AC;˘â&#x20AC;˘ure Setting. Control Valve Removed With the control valve removed the hand pump can be easUy coonected tothevalve. Refer to Figure 10 to determme the adapter required and install in the port next to the relief valve being tested. Check. setting as instructed . in steps 5 and 6 above.

Relief Valve Adjustment Checking Pressure Setting. Control Valve Installed 1.

The 011 in the hand pump Should be at room temperature, preferably 70"-80" F (21"-26.7" C). Also be sure the pump reservoir Is filled with Case TCH Fluid.

Lower all buckets and/or attachments to the floor. Then move control lever for relief valve being tested to relieve circuit pressure.

Loader Control Valve' The relief valves are adjusted by removing or addmg shims. The shims are installed between the plug and spring guide.

moved.

Break the line between the cylinder and control valve for the relief valve being tested at-any ccnvenient ccnnecUcn.

IT checking a loader bucket or boom relief valve, break line at a coonection that l eads directly to the control valve.

Remove plug from end of relief valve. IT con~ol valve is installed, use a magnet and remove spring guide/poppet assembly to be sure all shims are reAdd shims to mcr ease pressure setting or remove shims to decrease the pressure setting. Install spring guide/poppet assembly and

shims. (Continued on page 4011-29)

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LOCALLY I

1/4- HEX HIPfU

1/2" IIPT TO 1/4" IIPT REIIJC£R 11'2" IIPT TEE 11'· IIPT TO 7/16"-20 JIC, 37 AllAm' 1/ 16" -20 JIC. 37 SlIlYn fiTTING

1.21570

1/ 4" 10 BUUt HOSE ( DCUlL[ 11111£ 8RAID

nl-8] llH079

1/2" IIPT TO I/S" HPT REDUCER I/S" KEX Hlffl.£

218-900

M20671 218-10ll 635116

15 .

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~1J8· 1fP'T swna UIIlmf ......sorROEDER IUTT-GAU&E

1/16"-20 JTC-I/4" 11FT ADAPTER

TtST BlOCk FOR Of'F-w.otINE TESTING W£ BACIOIOE REliEF VALru CASE 1lAC1Ol0£ RaIEf VAUE

.-Figw'ei 8 - Hand 'Pulnp

I I I I I 1

. •-

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4002-28 Adapters Required to Connect Hand Pump to Control Valve Porta*

, 1/4" HAND PUMP HOSE

218-441 ADAPTER

PLUG

___ I WORK PORT

DRILL THE FOLLOWING PLUGS AND TAP THEM FOR 1/8" NPTF TO ACCEPT THE 218-441 ADAPTER. CONTROL VALVE PORT .cASE PART NO. STRAIGHT THREAD WITH O- RING

9/16" - 18 (3/8" TU8E) 3/4" - 161112" TU8E) 7/8" - 14 5/8" TUBE)

218-5155 PLUG 218-51 56 PLUG 218-5157 PLUG ..218-5158 PlUG 218-5159 PlUG 218-5160 PLUG 218-441 ADAPTOR

1-1116" - 12 0/4~ TU8E) - 12 (7/8" TUBE) 1-5/16" - ,12 (I" TUBE) USE IN EACH PLUG 1-3/16~

Figure 9 Adapters Required to Connect Hand Pump to Hoses and Tubes*

PLUG

, 1/4" HAND PUMP HOSE

218~R_~ -- ----, ~I

CAP

218-441 ADAPTER

'-8t}rnn-~

HOSE OR TUBE

DRILL THE FOLLOWING CAPS AND PlUGS AND TAP THEM FOR 1/8" NPTF TO ACCEPT THE 218-441 ADAPTER .

OTY.

CASE NO.

1 1 1 1 1 1

218-774 218-775 21 8-776 218-777 218- 778 218-779

QTY. J/8" TUBE PLUG 1/ 2" TUBE PLUG 5/8" TUBE PLUG 3/4" TUBE PLUG 7/8" TUBE PLUG 1" TUBE PLUG

CASE NO.

218-754 3/8" TUBE CAP 218-755 1/2" rUBE CAP 218-7S6 5/8" TUBE CAP 218-335 3/4" TUBE CAP 218-757 7/8" TUBE CAP 218-758 1" TUBE CAP 218-752 114" rUBE CAP *NOT.: ALL FITTINGS AND ADAPTERS LISTED ARE NOT REQUIRED FOR THIS MACHINE. PORTS AND HOSE OR TUBE THREADS WILL DETERMINE PARTS REQUIRED. 731195

1 1 1 1 1 1 12

Figure 10

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4002-29 4.

crease pressure setting or counterclockwise to decrease pressure setting.

Install plug and check pressure setting.

Repeat adjustment procedure as required to obtain correct pressure setting.

Backhoe Control Varve

"'"

Tighten lock nut while preventing adJusting screw from turning. Then torque nut to 50-80 Incb- pounds (5. 6-9 N m)

The relief valves are screw adjustable.

and check pressure setting.

Loos ~'

Turn adjusting screw clockwise to In-

lock nut.

Repeat adjustment procedure as required to obt.a.1n correct pressure setting.

BOOM LOCK RELIEF VALVE PRESSURE CHECK The pressure setting of the boom lock relief valve can be easUy checked using the hand pump illustrated In Figure 8,

The band pump must be operated a.ga.inst a solid column of oil. Actuate the hand pump to bleed air from the line and tighten connecU<.n.

Place boom lock control valve lever in the Lock position. Actuate the hand pump to buUd up pressure until the reUefvalve opens. Make several cbecks to obtain an accurate check.

If the pressure setting ls not as speci-

The oll In the hand pump Bbould be at

room temperature. preverable 70°-80. F (21°-26.7° CJ. Be sure pump reservoir is filled with Case Tea Fluid. 2.

Do Dot tighten connectioos at this time.

Lower the boom until the bucket Is resting

on the fioor. 3.

With the engine shut off. move the boom

coouol lever back and forth to relieve circuit pressures. ' 4.

Disconnect hose to tube to the rod end of the boom cylinders.

Refer to Figure 10 for the necessary parts and connect hand pump to bose.

fied OIl page 4002-3 the relief valve must be replaced. It Is nonadjustable and nonrepairahle. 9.

If leakage occurs past lock check seat out Inlet pJrt check for damaged lock check or seat.

LOADER MAIN RELIEF VALVE of the operators compartment to gain access to the test port in the control valve.

Pressure Check 1.

The hydrauliC oil sbould be warm (120· F (49- C) or control valve inlet tube should be very warm to the touch) to obtain an accurate pressure reading. To warm the aU. hold the control lever in Rollback for 15 seconds . then return to Neutral for 30 seconds. Repeat this cycle until oU temperature is as specified

Rest loader bucket flat on the floor.

Remove the plug in the right-band side

Remove the 1/4" pipe plug from the cootrol valve and connect a 3000 psi (20 680 kPa) pressure gauge to the test port.

Start engine and run ILt full throttle. Hold the control lever in Rollback posiUon and observe pressure gauge. The gauge sbould indicate 2300 :i: 50 psi (15 857 :i: 344 kPa).

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4002-30Âˇ-

Adjustment 1.

the screw out (cOWlterciock.wise) to decrease the pressure setting.

Remove the acorn nut and loosen the lock nul

When the pressure setting is as speci-

fied, tighten lock nut without disturbing the adjusting screw. Then install acorn nul

Turn the adjusting screw in (clockwise) to increase the pressure setting or turn

THREE POINT HITCH MAIN RELIEF VALVE indicate 1800 :

The main relief valve is located in the three point hitch control valve inlet/outlet section. To check the pressure setting of the relief valve, the test gauge Is connected to the test port in the loader control valve or to test port in pump protection valve. Figure 11. if equipped with three point hitch only.

:i:

344

Adjustment 1.

Remove the acorn nut and loosen the lock nut on control valve main reUef valve.

Turn the adjusting screw in (clockwise) to increase the pressure setting or turn the screw out (counterclockwise) to decrease the pressure setting.

When the pressure setting Is as specified, tighten lock nut without disturbing the ad-

Pressure Check The hydraulic oil should be warm (120Âˇ F

50 psi (12 410

kPa).

(49" C) or oontrol valve inlet oosesMuld

be very warm to the touch) to obtain an accurate pressure reading. To warm oil. oold the loader control lever in Rollback for 15 seconds or one of the hitch control valve levers. then rehlm to Neutral for 30 seconds. Repeat this cycle until aU temperature is as specified. 2.

Rest loader bucket flat on the floor, if so equipped.

IT equipped with a loader, remove the plug in the right-hand side of the operators compartment to gain access to the test ~rt in the control valve.

justing screw. Then install acorn nut.

Remove the 1/4" pipe plug from the cootrol valve and connect a 3000 psi (20 680 kPa) pressure gauge to the test port.

If equipped with three point hitch only, remove the 1/8" pipe plug at pump protection valve inlet, Figure 11. The pump protection valve is located outside the R.H. reservoir. .!,"

Start engine and run at full throttle. Hold the three point hitch lift crotro! lever in the Raise position and observe the pressure gauge. The gauge should

1. Pressure Test Port Figure 11

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4002-31

PUMP PROTECTION VALVE The pump protection valve is used on three point bitch only machines. The purpose of the valve is to prevent damage to the hydraulic pump if the hitch is removed and the roses at the rear of the machine are not CODnected together.

psi (0-34 4738 kPa) pressure gauge to test port. 2.

Start englne and run at 1000 to 1200 rpm (rimln) and observe pressure gauge.

The gauge should indicate 2600 (17 9264 i: 344 kPa).

The valve stx>uld rarely require repairor adjustment.

Pressure Check

Remove l / S" pipe plug at the valve Inlet port, FIgure 11. Connect a 0-5000

50 psi

Adjustment 1.

Remove acorn nut and loosen lock nut.

Turn adjusting screw in (Clockwise) to increase pressure or turn screw out (counterclockwise) todecreasepressure.

Wben the pressure setting is as specified. tighten lock nut without disturbing adjusting screw. Then install acorn nut.

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Section 4005 HYDRAULIC PUMP

J I Case

A Tennaco Company

E!~

C. E. Div. 9-66015 February 1976

............

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4005-2

TABLE OF CONTENTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . .. . . . . . Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information

Removal . . . . . . . . . . . . . . . . . • • • . . • . . . • . • . • . . . . . . . . • . • . . . . ..

. . Sbait Lubrication . . . Break of Rebuilt or Pump . • • . . . . . . . . · . . . . . . . . . . . . . . . . . . . . . . Identifying Causes of Pump Failure . . . . . . . . . .. . . . . . .. . . .. . . . . . . . . . Cessna Hydraulic Pump . • . . . . . . . . . . . . • . • · . . . . . . . . . . . . . . . . . . . . . . SpecifIcations . . . . . . . . • • . • • • . . . • . • • · . . . . . . . . . . . . . . . . . . . . . . General • . • • . . . • . . . . • . . • . . • • • • . • . · . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . .. . . . . . . ..

Installation

New

Operation . . • . . . . . . • . . . . . . • . . . • . • • • . . . . • . . • . • . • . . . . . • • • ..

Inspection

· . . . .. . . . . . . . . . . . . . . . . . . . . . • • . • . • . • . • • . . • • . . . • · . . . . . . . . . . .. . . . . . . . . . .

Assembly

.....•.••••.•...•...•••.....••••..•.••••••...•

Disassembly

....•....•..••.••...•

TRW Hydraulic Pump. . . . • . . • • • . . . . . • . . . • . . . . . • • • • . . . • . • . • • . •• Specificatlons

. . . ...

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .

General • . . • • . . . . • . . . . • • • • • . • • • . . . . • . . . . • • . • • . . . • • • • • • •

. . .. . . . . . . . . . . . . . . . . .. . . .. . . .. . . . Disassembly . . . . . . . . . . . . . • . • . . • . • • · . . . . . . . . . . . . . . . . . . . . . Inspection · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation

· . . ... . . . . . .

4005-3 4005-3 4005-3 4005-3 4005-3 4005-4 4005-4 4005-5 4005-5 4005-5 4005-5 4005-7 4005-8 4005-9 4005-12 4005-12 4005-12 4005-12 4005-13 4005-14 4005-15

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4005-3

GENERAL INFORMATION Thia machine uses pumps supplied by Cessna and TRW, Case part numbers will Dot be found on the pumps; however, there

is enoup diHerenee between the pumps that you wUl be able to Identify the pump you are working with.

PUMP REMOVAL AND INSTALLATION Removal 1.

Inatalation

Rest loader rucket fiat ontbe noor or

Lubricate the pump drive ahaft as Instructed under Shaft Lubrication.

Attach pump to auotion tube oose. Do not tighten clamp at this time.

Pivot pump into mounting bracket. Twist pump as required to engage the drive coupling. Install pump mounting cap screws and torque to 80-85 footÂˇpounds (108-115 N m).

Connect outlet oose to pump fitting and tighten all suction bose clamps.

If oll drained from reservoirs Is to be used again, -fUter the oil before returning it to the reservoir. If new oil is to be used, use o1l specified In Section 1050.

Break In .pump u lruItructed co page 4005-4. stop engine, cbeck for leaks aDd cheek reservoir 011 level and add oU 88

raise the loader arm and block in place with 11ft: cyllnder etqJa.

Have OD band clean containers and drain pan that will hold approximately 17 U.S. galloDs (64 liters), Then drain the right and left-hand reservoirs. Remove the grUle and lower guard. H equipped with a counterweight, remove cover plate at Tear of counterweight. The counterweight remains on the machine. DlBconnect DuUet bose from pump. TbeD

loosen outer bose clamps 011 each suction tube lower bose, 5.

-aemove the pump mounting cap screws. Pull pump from mounting bracket and

piV'Ot pump forward .

required.

auction bose clamp at pump and remove pump fr'om hose, Plug all bose openinp.

Loosen

Install the lower guard, cover plate at rear of counterweight if 80 equipped, and grille.

SHAFT LUBRICATION 1,

'!'be shaft spUnes must belubrlcatedWlth Molykote, Type G. (part DO. D60210) wbenever the pump Ie removed and tntJtalled or a new pump 18 tnstalled. ÂˇTo obtain maximum service life, the shaft. should be lubricated after 500 hours of

surfaces. Molykote. Type G . la a CODcentrate and exceaslve usage should be avoided. 4.

operation or six months of operatlon.

Prior to lubricating ahaft spliDes. remove all traces of oll, rust, dirt and any metal chips from the spllDes.

Do not rut splines with lubrioant. Moly. kote haa 8. peculiar afflnlty for-meW aDd when properly applied w:UI not 'Wipe off or squeeze out from between metal

Apply Molykote to the enUre length of the splines us1ng a STIFF brisUe brush. Bruah the lubricant into the spilDe. until they are well covered over their entire

surface:

THIS IS IMPORTANT. Brush

parallel to the epltnes. Wiping a quantity of lubrioant over _the splines IS NOT acceptable. 5.

lnsW.l pump iznlOrmal manner but do not allow dirt or other contamtnanta to come into contact with the lubricated surfaces.

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4005-4

BREAK IN OF REBUILT OR NEW PUMP 1.

start engine and run at balf throttle for

Neutral for five seconds. Repeat this cycle for three minutes.

three mimJtes. 2.

With the engine nmnlng at balf throttle, bold bucket control lever in Rollback to open the main reUef valve for five seconds. Then return control lever to

Inc rease engine speed to full throttle and repeat step 2.

Stop engine and check for leaks.

r.e

IDENTIFYING CAUSES OF PUMP FAILURE Particular attention Should be paid tothe following information if the pump bas a short service life. Any or all causes may be found In a pump that has bad a long service iUe.

Wear Caused by Fine Particles The J;!arlicles that cause abrasive wear are usuaI.iy not visible to the human eye, The fUter used on this machine removes particles over 40 microns in size, A micron equals 1 / 1000 millimeter or .0000394 inches. Improper service prreedures and fallure to follow the prescribed maintenance schedule can be the cauae of abrasive wear,

Wear Plate A narrow band with a sandblasted appearance will be evident around the bores in the wear plate. The edges of the lubrication slots will be rounded and the ends enlarged.

Gears A sandblasted appearance will be evident at the base of the teeth at each end, The bearing surface wUl have a dull finish as If s anded with fine sandpaper. A groove in seal Up area of the driveshaft may also be apparent.

Gear Housing The gear track will have a sandblasted appearance on the inlet side.

Wear Caused by Metal Particle. Metal particles usually result from wear or Insufficient flushing after a component fallure. Wear may be gradual or sudden depending on the quantity and size of the particles.

Wear Plate Circular scratches or grooving will be apparent near the outer edges, Depending on quantity and size of the particles, the entire surface may be heavily grooved.

Gears The bearing surfaces will have many small grooves. The severity of the grooving will depend on the amount of contamination and operating pressure.

Gear Housing The gear track. will be grooved by particles large enough to be caught between the tips of the gear teeth and the hOUSing.

Aeration or Cavitation This type of failure is rare and careful invest1gation is required to pinpoint it, Aeration occurs wben air Is mixed with the oU. Air can enter the system through a small leak in the suction line. Cavitation Is usually the result of the pump suction being restricted. Aeration and cavitation erode and pit the thrust plates and gear housings. Damage will be apparent on the suction side of the gear housing and on the high pressure (outlet) side of the thrust plates. As the air or vapor bubbles in the oil are compressed to pump discharge pressure they collapse. This collapse is called -an implosion. The force of the implosion removes metal from the thrust plates and the gear housings. A pump cavltatfDgor operatfDgon aerated fluid is usually noisy. It makes a sound like

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4005-$ pumping marbles. System operation Is spongy and jerky.

Lack of Oil Failure of this nature is usually due to a large air leak in the suction line. Heavy wear will be apparent on the end of the thrust plate and on both ends of the gears. Wear will be greater near the outside diameter of the gears.

Excessive Heat Excessive heat Is usually the result of a control valve spool not returning to neutral or a relief valve that Is set too low. If the valve spool faUs to return to neutral, the pump flow will be dumped continuously and 'Will cause

a rapid increase in oil temperature. If the relief valve Is set too low, part of the oil will be du.tnped across the relief valve every cycle. In this case loader operation may be slow.

Excessive Pressure There are two reasons for excessive pressure: (1) the relief valve fails to func tion. This produces one extreme surge of pressure and immediate failure. (2) The relief valve pressure setting Is too high and faUure is the result of repeated excessive pressure peaks. Both reasons for excessive pressure can result in broken drlveshaits or crackedhouslngs.

CESSNA HYDRAULIC PUMP (048950) SpecHications ~

.. . . . . . . • • . . . . . . . 24 U.S. gpm at 2000 rpm at 2000 psI (91 l/m1n at 2000 r fmin at 13 789 kPa) Tie bolt torque .......••••.•.•.•.• • • . . . . . . . . . . . . . . . 40 foot-pounds (54 N m) Mounting bolt torqUe . . . . . . . . • . . • • • . • . . . . . • . . . . . 80-85 foot-pounds (108-115 N m) Rotation . . . . . . . . . . . . . . . . . . . • . • _. • • . . . . . Counterclockwise viewed from shaft end. Wear allowance s . . . . . . . . . . . . . . , ..•: . . . . . . . . . . . . . See pages 4005-8 and 4005-9 Output . . . . . . . . . . . . . • .

General YIEW

The tv.'O gears revolve in a close fitting housing and trap oil between the gear teeth as the teeth move out of mesh. The all is carried around the edge of the housing and discharged at the ouUet side. Refer to Figure ·I.

Operation A bronze faced steel plate called a diaphragm reduce s gear end clearance by applying hydraulic pressure from the ouUet side of the pump. The area behind the diaphragm Is divided into pressure compartments formed by grooves in the face of the front cover. A rubber diaphragm seal and two gaskets are installed in the groove in the front cover.

Pressurized oil from the outlet side of the pump is directed to the diaphragm seal througb a drilled passage In the gear plate. The pressurized oil moves the diaphragm seal and two gaskets against the diaphragm.. The diaphragm in turn presses against the gear faces reducing gear end c learance and all leakage. Six smaIl holes drilled in the

HIGH /'R!SSURE OUTLET Oil

oq'!f!J UIII PRtSSURE INl(1' Oil

Figure I - Pump Operation dIaphragm equalize pressure on both sides of the diaphragm.

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4005-6 "

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13. IDLU GEAR 14. SEArl PUTE 15. TMRUSl' PlAT(

16. PORT ERD COVER

F igure 2 ·- Exploded View of-Ceesna Pump r

-....

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4005-7

A thrust plate is located at'the opposite side of the gears to absorb wear from the gear faces. The six holes in the thrust plate maliitain equal ,p ressure on both sides of the thrust plate. . .LJ: '4. Two 'ball type relief valves locl'ated in the front cover prevent shaft seal blow out. One relieves into the suction side and the other into the outlet side. When the gear shaft lubricatIon pressure exceeds either the.-..suctlon pressure or the outlet pressure, one of the steel balls wlll be forced from its seat and oil will flow past it.

,Scribe a

Disassembly 1.

Hoe across the three sections

1. 2.

DRIVE GEAR DRIVEN GEAR

3. 4.

..of the pump so that_the drive eDd cover,

. port end cover, and gear plate can

COVER

.reassembled in the same position.

Figure 4 - Drive End Cover Removed

SCRIBED LINE

. .Figure 3 - Disassembling Pump

Use a standard 7/16"; 12 point socket -,to remove the eight capscrews that hold - the pump together. ~

GEAR PLATE DRIVE END

Use a soft metal hammer, tap the front cover from the gear plate. DO NOT-try to pry sections apart. as the "machined ~aces will be, d~aged ...... F1gure ~.

To separate port cover from gear plate, tap end of driveshaft with soft hammer . coCk~on dowel .Do not allow gear plate P,..I ns. Figure 5. ,~.~

3. 4.

THRUST PLATE GEAR P,l.ATE

Figure 5 - Gear Plate and -' Port End Cover

Slip a sharp instrument under the diaphragm on the dfive ena cover and gently pry the diaphragm loose, Figure S. Remove the SJirings and calls, backup gasket; Âˇ protector gasket. and diaphragm seal. Discard the gaskets and seals, Figure ( " -- -'';'' ' -_

-"RemOve and discard~the shaft seal from the dr ive end cover, Figur e 8,

... .-:, .

PORTEND COVER SUCTION SIDE

,."

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Inspeetion Clean all parts and inspect for nicks and burrs. Remove all imperfections on machined surfaces with fine emery cloth. L

Inspeot the driveShaft. Chec k the splines for small cracks. wear at Shaft seal contact area, and rough spots. Inspect the idlet: gear and Shaft. Figure 9. If the bearing area of the sbaft measures less than .873" (22.17 mm). the

shaft and gear assemblies Should be replaced. Check the gear ends for sebring. 1.

SPRING DRIVE END COVER

3. 4.

bluing due to beat, and excessive wear. Check gear width. if less than 1.517" (38.53 mmH replace gear. Make sure the snap rLngs are in place. If the gear teeth bave shazp edges. break c orner with eme.ry cloth..

GASKETS AND SEAL DIAPHRAGM

Figure 6 - Removing Dlaphragm (Wear Plate)

o ,1.

1. 2.

PROTECTOR 3. GASKET BACKUP GASKET

DIAPHRAGM SEAL 2.

REPLACE GEAR ASSEMBLY IF SHAFT DIAMETER IS LESS THAN .873" (22.17 mm) REPLACE GEAR ASSEMBLY IF GEAR WIDTH IS LESS THAN 1.517" (38.53 mm) SNAP RING .

Figure 9 -

Driv~n

Gear Assembly

NOTal Shafts and gears are serviced as an assembly only, and are not available separately.

Figure 8 - .Drlve End Cover and Shaft Seal

3. '"" Inspect -the 'diaphragm and thrust plate. Check i'or score marks and erosion pits. --.. If noticeably eroded _ in center, deeply scored or bJ.rned, -replace. • • 4. Inspect the bushings in both the drive eod and port end covers, Figure 11. If the bearing inside diameter is more

0 '

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4005-9

than .879" (22.32 mm), both the drive end and port end covers must be replaced as an assembly with the bushings. Bushings are not supplied separately,

, ..

.. 1.

REPLACE GEAR PLATE IF EITHBR GEAR POCKET DIAMETER IS MORE THAN 2.107" (53.5 nun),

Figure 12 - Checking the Gear Plate 1.

ERODED AREA

Assembly

Figure 10 - Checking Dlaphragm ..•

','

Place a new diaphragm seal on the drive end cover with the groove down.. Use a dull

instrument

and

work s eal into

grooves J.n cover. Install new protector gasket (thin) on the diaphragm s eal, Install new backup gasket (thick).

•

REPLACE COVER IF EITHER ,BUSHING DIAMETE R IS MORE THAN .879" (22.32 rom)

- 19l1,!.\

Figure 11 - Checking the Bushings 5,

Inspect the gear plate. Figure 12. Check

inside diameter of plate for excessive wear Of sc ore marks. If inside diameter of gear pockets measures over 2.10.,,, (53. S mm) . replace.

1. DIAPHRAGM SEAL 2. PROTECTOR

3. BACKUP GASKET (THICK)

GASKET (THIN)

FIgure 13 - Installtng Diaphragm Seal

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4005-10

Place one ball in eacb hole in the drive end cover. Place a spring on top of each ball

Notice that the gear plate has two half moon cavities on one side, Also the small hole drilled in one of the cavities. matan gear plate on port end cover with half moon cavities toward end cover and drilled hole on the outlet (pressure) side, Figure 16.

1 ---') ""--"

Figure 14 - Installing Balls and Springs 3,

Install new diaphragm (wear plate) With the bronze side up. It must fit inside of the rim on the diaphragm seal. Make sure coils of the springs are not wedged between -diaphragm and front cover. Figure .Qn_ the port end cover, install the thrust

plate "(wear plate) with bronze side toward the gears, Side with cutaway must .' be on the suction sIde of the pump. Fig- -. ure 16. Tbis plate fits inside the gear plate v.'b.en gear plate Is seated on rear cover.

1. SPRING 3. 2. DRIVE END COVER

5, HOLE - MUST BE ON OUTLET SIDE

Figure 16 - Port End Cover and Gear Plate

15.

1. roRT END COVER 4, GEAR PLATE

2. SUCTION SIDE 3. THRUST PLATE

Lubricate gears With clean hydraulic oil and install gears in port end cover.

Install drive end cover over gears. install cap screws and torque evenly to specification on page 4005-5,

Figure 17 - Installing Gears

DIAPHRAGM

Âˇ8. Figure 15 - Front Cover and Diaphragm

Install seal protector (sleeve. tape, etc.) on pump shaft. Carefully install seal

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4005-11 •

over the Shaft. Use a 1-5/16" (33.3~ O.D. seal driver and hammer, tap the

:iJ .,j lUse... suitable tool and rotate the pump shaft 10 revolutions. Pw:up Should be almollt .free enough to rotate Shaft by band. If not. disassemble pump to f1Dd the cause of the bincl,

seal into drive end coveT unW &eated against shoulder in seal bore.

1 "

., "

r,; i.! '"

.... -

,,..

.•

••

'(:._1

I;: ~

"'1';;'"

•

"1-0 .,. ,.

-'"';j+. :

.. ..'

:.."

_b.

.,..

.:.~

,I'

•,

,'"

tt~

•

,'"v . •

-..

.;; • '{

•

·1 "~ :-.

~-~~:""

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4005-12

T RW HYDRAULIC PUMP {D492411 Specifications Rated output • ...

. . • • • • • • • • . • • • • • • • • . .• 24 U.S. gpm at 2 000 rpm at 2000 psi (91 l/min at 2000 r fmin at 13 789 kPa) Tie bolt torque ..• . . • . . • . • . . • • • • • . . • • • . • . • • • 25- 35 foot-pounds (34-47 N m) Mounting bolt torque •. • .. • •• . • .• •• ••••.•••.• . . . 80-85 foot-pounds (108-U5 N m) Rotation • . • . • . . . , , • . , , • ••• • •• • , • .. Counterclockwise viewed from shaft end. Wear allowances . . . . . . . •..• ••.••• ..• ..• . •••....••. .• • Refer to Inspection.

General

oil groove cast into the end cover by the two slots and groove in the pressure plate. As discharge pressure increases hydraulic pressure forces the s eal package against the gears and prevents leakage from the pressure side to the suction side of pump.

The two gears revolving in a close fitting housing trap 011 between the gear teeth as the teeth move out of meSh. The oil is carried around the edge of the housing and discharged at the outlet side. Refer to Figure 1.

Operation A bronze faced plate called a pressure plate reduces gear end clearance by applying hydraulic pressure from the discharge side of the pump. A seal package consisting of a rubber web seal, two paper backing webs and a Phenolic backing web is pressed into the 011 groove in the end cover. on from the dIscharge side of the pump is directed to the

1. PRES SURE PLATE 2. SEAL PACKAGE 3. END COVER 4. SEAL PACKAGE IN

GROOVE

Holes in the pressure plate permit pump 011 to fll1 the pressure "compartments" formed by the seal pack. With pressure on both sides of the gear plate thus equalized, the pressure plate maintains contact with the gear sides through all pressure ranges. A positive pressure on the shaft seal is maintained by the oil passed through the end cover shaft buShings and a check valve in the driven gear shaft.

5. HYDRAUliC OIL ENTERS GROOVE HERE 6. OIL UNDER SEAL PAC KAGE FORCES PRESSURE PLATE AGA INST GEARS I ,!"~

Figure 18 - Gear Loading

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•

4005-13

•

,0\j [:J'

,.,...

1. 3' . · (19 ,1 _l l OlC eN' SCIt£l/ (4) 2. 1-1/. · (" . 5 _ 1 l(ItG CAP SCREW (4J

4. 00

5. PR£SSUIU: PlATE

6. 0-_111&

9. DOi/El.

. 10. BOOT

1. ORlvt &EM

•. ORIYVI 'EAR

COV[R

Figure .19 - Exploded View TRW Pump

Disassembly

,",

Scribe a mark on the end cover and body to assure proper reassembly. . ,~-_-

Remove the eight end cover mounting bolts (four long and four Short).

Using a soft lia:mmer. strike the moUnting .ears alternately to separate the end cover from the body.

Remove the pressure plate and D-ring from the end cover.

or cbeck valve from the driven gear.

DO NOT attempt "to remove :., the. seal package from the end cover . NOT.:

. "These parts are serviceable only as - part of a new end cover assembly.

SEAL PACKAGE rnSTALLED Remove the drive and driven gears from the pump body. Do not remove the spring

Figure 20 - Seal Package

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4005-1.

Inspection

Gears

Body

Cbeck the sealing surface for nicks and burrs. Ifnicks or burrs us noted, remove with a piece of crocus cloth or flat lnd1a stone.

Measure the diameter of both gears. U either gear has a diameter less than 2.1203" (53.8 mm) the gears must be replaced.

Clean the body in cleaning solvent and all passages are free of foreign matter.

Measure the diameter of the gear journals. Ii the diam.eter of a journalls less than 0.8737" (22.2 rom) the gears must be replaced.

Measure the thickness of both gears. If one gear measures less than 1.5110" (38.3 mm.) the gears must be replaced.

make sure

Using an inside micrometer, measure the gear bores. If either bore diameter exceeds 2.1253" (54 mm), We body mustbe replaced.

NOTE; The thickness of the gears must mell8UZ"e the same within 0.0005" (0.013 nun).

Check gear faces and journals for scoring. Replace the gear set if heavy scoring Is evident. The gearteetb. shouldbave Sharp corners and not rounded.

End Cover NOTe: DO NOT remove the seal pack-

age from 1I:I.e end cover. These parts are not serviceable Items. 1.

1. 0. 8777" (22.3 mm) 2. 2.1268" (M ~. .

2:-- Check the sealing surface for ruckS and huTs. If nicks or burrs are noted. reIDOVe with a pIece of crocus cloth or nat India stone.

IIlD!>

Figure 21

',: 1"~

Using a depth micrometer, Dleasure !he depth of the geu bores. If either oore

Using an insidemJcrometer, measure the diameter of the gear tuShLngs. If either buShing exceeds 0.8777" (22.3 mm) in diameter the body must be replaced

Using an insIde micrometer. measure the bushing diameter. If either bushing exceeds 0.8777" (22.3 mm) in diameter the end cover mJ.st be replaced.

Inspec t the sbaft seal for cracks. deterioration and other defects.

H the pump has been disassembled because of low output and the pump body and gears are found to be serviceable, it can be assumed. that the seal package

depth exceeds 1.5155" (38.5 mm) the body must be replaced

Use a lint tree cloth moistened with cleaning solvent and clean end cover. Do Dot submerge in cleaning solvent or dry with compressed air.

Is probablydetectlve. requiring end cover replacement.-

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4005-15

Inspect the pressure plate for scoring; pitting and excessive wear.

Assembly 1.

Position gears in body as shown in Figure 22. -The check valve spring in the driven gear must be up.

1. PRESSURE PLATE MUST BE mSTALLED AS SHOWN Figure 23 - Pressure Plate Installed

5. ( ).

1. CHECK VALVE SPRING MUST BE UP

Secure the end eover to the body with the eight ferry head bolts (four long and four sbort). Torque the bolts evenly to specification on page 4005-12, Torque boits in secr.tence as Shown in Figure 24.

Figure 22 - Installing Gears

If the Shaft seal was removed, press ina new seal. The seal must be square tothe bushing within.002" (0.051 mm) and pressed in .0 10"-.020" (0.254-0.508 mm) below .the edge oC the seal bore.

Coat the smooth side of the pressure ~ plate with a Ught, clean grease and position on end cover as Shown In Figure "23. Then coat the O-ring witb grease and position In groove formed by the pressure plate and end cover.

.Set body on work bench with gears up and inBtall end cover over gears being eareful Dot to damage the shaft seal When end cover starts on dov.rel pins invert the pump and set the pump on open Jaws of vise. Strike the body with a soft hammer untll the body is seated against the -end cover.

Figure 24 - Torque Sequence

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Section

4007 LOADER CONTROL VALVE

J I Case

C. E. Dlv. 9-66015

ATen".coCompany

February 1976

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•

TABLE OF CONTENTS Specifications .....•• • • . . . . . . . . . . . . . . . . . . . . . • • . . . . . • •••••• • •.•. 4007-3 Special Tools . . . . . . . , . . . . . . . . • . . . . . . . . . . • . • . . . . . . . . • . . . . . . . . . . 4007-4

General ., .....•.• .• ••.•..•.•••.• . • . • . . . • . • . . . • . . • . . . . . . . . . . 4007-5 Operation . . . . . . . . . . .

. . . . . . . . . . . . . •.•.•.......••.•.•.••••.

4007-6

Main Relief Valve ... , . . . . . . . . . . . • . . . . . . . . . . •... . . ..•. •. ... , . 4007-6 .._

AY;;.f

Acb.Ja~d

Oil Flow - Bucket Spool

1 1',

..••••.••~ •••

, '•.•••••. ••• • •••.••. 4007-7

Oil Flow - Lift Spool Actuated . . . . . . . . . . . . . . • • . . . • • • . . . • . • . • • • . . 4007- 8

-.'"

Oil Flow - Lift Spool in Float •..•••.": :-:•• .~ .. ~,

• • . • . • • • . . • . . . . • • • • . 4007-9

Float Detent . . . . . . . . . . . . . . . . ..•••.. . ..•..• • • • . • . • . • . • . • . . . . 4007-9 Secondary Relief Valve

Servicing the Control Valve

....... .... ....

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4007-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4007-10

~.,.

Removal •...• , •....•• " .•• , _. .. . ' " .... _.r •••...• • • • •

~ • , •••••••••••

4007-10

Disassembly . . . . . . . • . •' . • . . . . . . • . , •.•. • ' . . . . . . . , . . . . • . . . . . . 4007-10

LlftSpooI ......•

,~ . ;

.. ...••• .... , .. . . .... . . . • . • . . . . . . 4007-10

. . . . . . . . . . . . . , .. . . . . . . . . . . . . . . . . . . . . . .'. . . . 4007-11 . . . . . .-. . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . 4007-13

Bucket Spool , Clam Spool

Main Relief Valve

. . . . • . . _ •• . . . . .•.•.•• .. •. . • . • . • . . . • . . . . 4007-14

Secondary Relief Valves . . . . . . . . . . .. .. . . . . . . . . . . . . . . . . . . . . . . 4007-15 Load Check Valves . . . . . . . •...• .. ••.•. .•.•. . . .. • . . . . . . . . . . 4007-16 Inspection . . . . . . . . . . . . . • • . . • . . . . • • • . • • • . . . . . . . • • . • • • . . • • . 4007-16 Assembly . . . . • . . . . . . . . • • • . • . . •.. '•.•• • •• • •

••

.•.•. . •••.• 4007-17

Load Check Valves ....•••• " ••.•.. . .•.•••.•...•.•.••••..•• 4007-17 Sec~ndary

Relief Valves •.• _ . . •• _ •..•• _ •. -• . • . . • . . • _ ••••.. __ 4007-17

MaiD Relief Valve

. _ .•.. . • • • . • • • . • • . • . . . . . . • • . • • . . • • . . . • 4007-18

Clam Spool • . . . . . . • • •. . _••• : •. ' ,' •••.• ,....!

• ~ : • . . • • • _. _. . • • • • • • 4007~19

Bucket Spool . . . • . . ..•..•••.•. ••••.•••••••••• " •••••.• ' ••• 4007-19 ,<:!'

Lift Spool . . . . . . • • . . . . . .•. • ••••• . ...••.•.,""'...... _. • . • . • • . . . . 4007-21 Installation

. . . . . . .. .

. . . . . . . . . . . . . . . . . . . . .. .. .. . .. . . . . . . . . . 4007- 22 - 'or."

'.)

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4007-3

SPECIFICATIONS

Relief valve pressure settings Main relief valve . . . . . . • . . . . . • •• . . . • . . . . . • . . . 2300 :i: 50 psi at full throWe (15 857:1: 344 kPa at full throttle) Secondary relief valve, bucket spool A and B ports •. ••. • . • .•.• •. ... Hand pump setting - 2100- 2300 psi ~

... .."

(14 479" - 15 857 kPa)

on temperature for pressure check . f!".f Maill relief valve • .• . . .. .•... ;'-:"'. .... .. .. . . . . .. .. .. 120' F (49' C) Secondary relief valve . . . . . . . • . • . :- .••.. • . . Room temperature. prefer ably

70· - 80' F (21 0

26.7" C) Spool. and ports __ Spool travel , neutral to pressure ••• . .••..••.•••••• 3/8" (1 0 rom) in and out Spool in . . . . . . • . . . . . . . . . . . . . . . • . • . . . . . . . . .. A p:>rt pressu.rized Spool out . . . . . . • .•••...•••••••.•.•••••.•..•• B port pressurized Spool travel. neut ral to Ooat •.•.... • . .•.. .. • . • .. . . .. . 11/16" (17 mmJ Port threads All 'WOrk ports . . .• •• •• . • • •••• , , ••••• •• ••• ••.• " 7/8" - 14 straight Inlet port .• , ...•• . . . . . . .. . " .• , .. , •• •. , .. " 1-1/16" - 12 straight Outlet port, power beyond . , . , .. • , •• " • .. ••.. , . , 1-1/16" - 12 s traight Power beyond fitting. internal • ••.. •• " . . • " . . . 1-1 /16" - 12 straight Outlet port. return oil ••• . . . . . .. .. • . . . .• .. .. . . . . 1-1 /16" - 12 straight Weight (approx.) Compressed length 2 spool valve . . . . . . . . . . . . . . . . , .. ,. , •• .• , .• • ,. .. . . . . . 28 1bs. (12.7 kg) 3 spool valve .. . ••. " ., .... _ . -•.•- . . . . . . : . . • . . . . . . . . .. 361bs. (16.3 kg) Springs Main relief plunger , • , , . , : •• , , , • .• ' , , , . . . . . .. .• .. ,. 13/ 16" at 4 - 6 Ibs . (20.64 rum at 1.8 - 2.7 kg) Main r elIef poppet . . . . . . . . . . . . . , • , ••.•• • • , , • , •• 11 / 16 " at 25.5 - 28.5 lbs . (17. 46 mm at 11,6 - 13 kg) Secondary relief , •... , . , , . , . . . •••..•• , •• .• . , 27/32 " at 145.5 - 178.51bs._ (21.43 nun at 66 - 81 kg) Detent . . . . . , . , • •.•••• • • .••. "---' , , . . . . . . . . . • . . . 1-3/8" at 153 - 187 lbs. (34.9 mm at 69 - 85 kg)

U.S. and Metric Torque Specifications Hydraulic Fittings (Steel) D... Sbe

Tllbe 0.0.

Hose I.D.

1/4"

37" Flu-e Torque

.T hread

S"' -

.. • "

.'.'

Ft-lbs

Stn.tgbt Thread O ·rll1lJ Torque

Ft_lb.

12- 19

16-25

16_25

22-33

7/16"-20

6-U

8-16

•

5/16"

'112"-20 ;iI

8 _16

1 1- 21

3/8'' - -

9/16''-18

10-25

14-33

25-4.0

34-5-4

1/ 2"

3/ 4"-16

15-42

20 - 65

"2-67

57-90

5/8"

' '1/8''-14

2 5-58

34.-'18

58_92

79_124

3/ 4"

1-1/ 111"-12

",,0_80

54_108

80-128

108_1'74

1 / 8"

1-3/ 16"-12

60_100

81-135

100-160

136-216

1-5/ Hi"-12

75-11'1

102-U8

117- 187

159_253

1-1/....

1-5/ 8" -12

125-165

169-213

165-264

224---357

1 - 1/ 2"

1 -7/8" _12

210_250

285_338

250-4.00

339 _5-42

'. ;

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4007-4

SPECIAL TOOLS The

lustrated

tools

(kit

part

no. D45700) U-

in Figure 1 are available from

Service Parts SUpply to aid in servicing the loader control valve.

-690154

690155 690156

Figure 1 - Special Service Tools

COIllTAMIIIIATED OIL CAUSES PROBLEMS 1.

Cle8Jl dipstick or level plug &rea before checking oil level.

Clean reservoir ftIl area before adding oiL

Use a clean funnel and container when adding 011.

Clean exterior of components, lines, and fittings before removal. Clo se openings with c lean caplurs.

Make repaIrs on a clean work bench. Use clean tools.

Change oil and service iIlter(s) when making repairs.

IT drained oil is reused, it should be filtered before reinstalling in reservoir.

NOTE:

If ps ;Âˇts Il'lspectrnn. tncttctrtes that metat-chip:s;-shredded-pa.clHftg-. etc. have entere<t the bydraulic system, the system should be flushed. filter(s) serviced, and new oil installed. 7CII V

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4007-5

GEN ERAL The loader control valve is a two spool (three spool with clam bucket and spool located on the outlet side of the lift spool) open center, series parallel val ve. The parallel passages are the return passages at the top and bottom of the valve, Figure 2. In this valve all oil is directed to the cylinders being actuated. If more than one spool is actuated, the spool closest to the inlet po rt receives the oil. Example: When the bucket spool is actuated, no oil is available at the lift or clam spool until the bucket spool is returned to Neutral. The same would be t r ue of the clam spool if the lift spool were actuated. The valve contains two outlet IX>rts, one connecting the work port return passages to the reservoir r eturn line and the open center outlet which contains a power beyond fitting. The power beyond fitting permits the installation of rear mounted hydraulics without additional valves to control oil flow. It also permits the use of the main relief valve to protect the backhoe hydraulic system from excessive pressure. However, only one sys-

tern can be operated at one time--actuating a loader control valve spool blocks oil flow to the rear mounted hyd r aul ic system. An adjustable, pilot operated main r elief valve at the control valve inlet prevents excessive pressure in the hydraulic system whenever a spool is actuated.

Load check valves between the work ports lUld the spools prevent reverse flow of o il between the cylinders and the control valve as a spool is moved into a power position. Secondary relief valves are connected to the A and B ports of the bucket spool to protect the circu its when a cylinder is fo rced to move with the spool in Neutral. Control valve operat ion Is discussed and illustrated on pages 4007-6 through 4007- 10. With the loader control valve spools in neutral, oil flows straight t hrough the open center passage and the IX>wer beyond fitting to the rear mounted hydraulics control valve(s) to t he reservoir.

LOAD CHECK VALVE ONLY IN LIFT AND CLAM SPOOL A AND B PORTS r'WY--lIAI"':J

RETURN

PASSAGE B PORT

A PORT IL~___W*~~i1tt!r< ~ETURPI

PASSAGE

PUHP FlOW STAT IC OIL

SECONDARY RELI EF VALVE AND

LOAD CHEC K VALVE I ~ BUCKET SPOOL A AND B PORTS

Figure 2 - Oil Flow - Spools in Neutral

4007-6

OPERATION Main Relief Valve The main relief val ve is located at the inlet of the cont rol valve. T he valve JX>ppet protrudes into the open center p assage as illustrated in Figur e 2.

then unseats the poppet and oil is diverted through the seat sleeve to the r eservoir. 4.

The relief valve will remain open until the cylinder moves or the control valve spool is returned to neutral.

The main relief val ve is pilot operated. This means a spear s haped pilot plunger controls the pressure at which the val ve opens and permits a g radual opening of the r elief valve. Note that a small hole is dr illed through the poppet. This permits the same pressure to be maintained on both sides o f the poppet during normal operation and helps control the gradual opening of the relief val ve when pressure reaches the specified setting. When a cylinder reache s the end of its travel or is held for any reason with the control valve spool in a power position, the main relief valve opens to prot ect the hydraulic system from damage. When the relief valve is open, on is dlvertedto the reservoir.

~fim~~L 1. PRESSURE UNSEATS PLUNGER

~~ii-ct-

P!UlT

2. LOli OIL SUPPLY AND FAST BLEED OFF PAST PLUNGER CREATES PRESSURE DIFFERENTIAL 3. PRESSURE UNSEATS POPPET

When pressure in the open center passage reaches the pressure s etting of the relief valve. the p Uot plunger is fo r ced off its s e at.

OU flows through the plunger seat faster than 1t can be s upplied, creating a pressure differential (lower pr essure) between the popp~t and plunger.

The pressure in the open cente r passage

AND OIL IS DIVERTED TO THE RESERVOIR

HIGH PRESSUPE Oil PRESSURE DI FFERENTIAL RETURN OI L

Figure 3 - Main Rel ief Valve Operation

4007-7

Oil Flow - Bucket Spool Actuated Figure 4 shows the bucket spool fully moved into the valve body, c ausingtbe bucket to be dumped. The effects of the spool movement and oil flow within the valve are as desoribed under Oil Flow - Lift Spool Actuated.

In addition, all flow of oU from the pump to the lift spool is blooked by the bucket spool. For this reason, it [s impossible to raise the lift arms When the bucket spool is fully actuated. In m achines equipped with a clam buc ket and three-spool valve (not shown), oil flow to both the lift and clam spools is blocked whe n the bucket spool Is fully actuated.

'endlyCJ)s BUCKET CY LlNO£R

•

PUMP FLOW RETURN OIL STATIC OIL

Figure 4 -

75157)

Flow - Bucket Spool Actuated

4007 -8

Oil Flow Lift Spool Actuated

to the r od end of the lift oylinders causing the loader arm to lower.

In Figure 5 the lift spool is moved into the val va body which:

3..

Blocks the op en c enter passage. With open center blocked, all a U from the pump flows to the spool being actuated. A.s pressure in the open c enter pasage iIlcr eases. the load check poppets open , perm itting au to flo w to the A port. From the Aport. aU is dir ected

LIFT

Simultaneously, the B port is opened to the r eturn p assage, allowing aU displac ed fro m the closed end of the lift cylinders to return to the rese rvoir.

When the spool is returned to neutral , aU is locked between the control valve and 11ft cyl inders, preventing further movementofthe loader frame. To raise the loader frame. the spool is moved out of the valve body and o il flow is reversed â&#x20AC;˘

â&#x20AC;˘

PUMP FLO!o!

RtIlJRH OIL

CVLINDER

STATIC OIL

Figure 5 - OU Flow - L ift Spool Actuated

4007 -9

Oil Flow - Lift Spool in Float When the lift spool is in the float position. oil from the pump flows through the open center passage to t he outlet. The two work ports a re directly connected through the oollow center of the spool. Openings next to t he narrow, outer lands permits oil to enter the hollow center of the spool. Oil in the lift cylinders is then free to flow through the spool in either direction. Another opening which is posit ioned in the r eturn passage allows a small portion of oil to be diverted to the reservo ir. The loader frame will lower because of its weight if raised. or follo w the contour of the ground as in back filling.

â&#x20AC;˘

PUMP FLOW OIL TRANSFERING BETWEEN ENDS OF LIFT CYLINDERS STATIC OIL

7515 53

Figure 6 - Oil Flow - L ift Spool in Float

Float Detent The flo at detent holds the lift spool in the float position mec hanically. Refer to Figure 7. As the s pool is pushed into the val ve body. the detent stud forces t he steel balls outward. allowing the s pool to be positioned in float. When the ridge on the detent stud passes the balls , t he detent spring and the tapered surface of the detent cam hold the balls in t he groove on the stud, preventing the spool from returning to neutral when the control lever is rel eased. A Ught tug on the control lever will allow the spool to r eturn to neutral.

mined by the position of the adjustment plug in the detent housing.

1. SPOOL 2. DETENT STUD 3. STEEL BALLS(B)

4. RIDGE

The

DETE ~T

SPRING

6. DETENT CAl'!

7. ADJUSTMENT PLUG

amount of pressure required to

engage or disengage the detent is deter-

Figure 7 - Float Detent (Spool1n Neutral)

4007- 10

Seeon

ry R lief Valve PUMP FLOW

Seoondary relief valve are connected to the A and B ports of the bucket spool.

PRf Ssu ItE FrulM

ROO END OF

BUCKEr CYLIHDERS RETURN OIL

STATIC O!L

The relief valves protect the hydraulic ciroults, and the bucket and related l inkage from damage due to excessive preasurewhen the bucket sfK>Ol Is m Neutral . Refer to Figure 8. Assume that the loader arm is being raised and the bucket is held by an immovabl e object and the following actions take place. 1.

Pressure in rod end of bucket cylinders rises to pressure setting of reUef valve.

RelIef valve poppet is unseated.

Pistons move in bucket cylinders (allowing bucket to move) because on can be displaced from the pistons through the relief valve.

Poppet closes when buoket moves past the obstruction.

A PORT ~~_~~'""~~~ POPPET UNSEATED BV . F.....~ P RESSU R[ IH ROO [If 0 OF BUCKH CYl [/(OERS

BUCKET SPOOL [N NEUTRAL 75 I ss.c.

F1gure 8 - Secondary R elief Valve Operation

SERVICI G THE LOADER CONTROL VALVE Removal

Disconnect inlet hos e

at tee fitting.

Remove accumulated dirt from the control valve and surrounding area.

Rest the loader bucket flat on the floor.

Remove nuts and washers from valve mounting bolts and bold valve in place. T hen r emove spacers and washers from top of val vee

With the engine stopped. move the control lever(s) in all directionS to equalize c1.rcuit pressures.

10. Disengage valve from 11ft oylinder tubes and remove valve.

Swing battery out of way for easy access to the control valve .

Disa sembly

4. 5.

Disconnect control linkage at the spools. Disconnect magnetio detent wiring from harness.

Remove the two outlet tubes.

wosan lift cylinder tube clamp on frame. Disconnect oylinder tubes and hoses at oontrol val vee

Lift Spool 1.

Remove the detent adjusting plug and spr ing from the detent housing. Figure

9. 2.

Remove the dete1'\t spring, cam, steel

balls (8), and detent washer from the

detent bouaillg.

•

4007-11

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. ~

. . 1(-

I~ ,. :::' _j

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15 iQ))~' 10.

IMER I).RIHG RHAI NER

2. DETENT SPRING

11.

SPOOl SLEEVE

D€T!Nl CAM

12 . 13.

GLAIID WIPER

S. 6. .,. 8. 9.

OETEf(! VASII£lt DET£/fT ItOOSI HG

IS.

SPRI IfG SEAT

16.

CENTERING SPRING

PLUG

4. STEEL BAllS (6)

1( , WIPER RETAIKER

SPOOl.

M ER o-RIHG RETAINER O-RIHG

11. DETENT STUD

Figure 9 - Ll!t Spool

Unscrew detent housing from .oontrol valve,

Bucket Spool

Grasp spool centering spring and pull sIX'ol from valve body. Then remove the two O-ring retainers and O- rings from the spool.

without removing the 11ft spool det6l.t housing. Loosen the detent housJng lock nut; then unscrew spring cap and pull spool from valve

NOTE: The bucket spool can be removed

body and pl'!oceed to step 3,

1. 5.

Do not remove the centering spring unless 271 (red) Loctile is available .for use during assembly. To remove the spring, secure the spool.in a: soft jawed vise and install the spring compressor shown in Figure 1. Compress spring

Remove gland. O- ring retainer and 0ring from va!ve body.

Loosen spring cap lock nut and unscrew COlUlector from spring cap.

Secure s:pring cap in a vise with the spool horizontal. Be careful not to distort the sprlng cap.

Pull the cOlUlector/detent assembly awsy from the spring cap. Push the spool into the spring cap to expose the link to spacer roll pin and drive the pin out of these parts. Have someone hold the detenthous1ng to prevent it from falling to the floor.

and unscrew the detent stud. Remove spring compressor from spring. 6.

Remove spool gland and sleeve from control valve. Then remove the w.!per retainer, wiper 'a nd O-rings from the gland. Do not remove the spool eye. The eye and an O-ring are not serviced.

Unscrew spring cap from valve body and pull spool from body.

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4007 - 12

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.(.).

...

>,'

.... ,

.... ";I:

.... .",

. ~C§) ~ l. 2. "l.

6LANO

O.RIItG RETAINER o.RTN~

•• 5I'00I. _ 5 . •SPltIH6 SEAT • 6. CEHTEIJI«l SPRJ"i

·.... · .

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-~.,

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• '1. SPACER 8. SPRING stREli 9.

LlKK -

10. ROLL-PI" 11. SPIll", tAP J2. Loa: 1M

...". H.

". ". ".

"""

- .

covr,

'AS"" SW COil lOIS IH& LIn SOWI

-...Figure 10 - Bucket Spool

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OCTOO HOUSJItS

CONlttTOR

.,.

.",

".ZO.

SPACtR

... """" zo. ... '"'

21 • COIL IlJUSIHG COIL

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DETrN'T STUD

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4007-13

slot in coil housing or the leads may be cut off during removal.

Remove the spring cap. To remove the centering spring. secure the s\XIOl in a soft jawed vise and in-

11. Remove detent stud and spacer assembly.

stall the spring compressor illustrated in Figure 1. Use a pair of pliers or vise grips and remove the spring screw. Use care not to distort end of screw. Remove spring compressor from spring.

12. Remove lock nuts from connector and remove connector. Check condition of 0 rfng on connector and replace if necessary.

Clam Spool NOT.:

Do not disassemble the detent

assembly unless necessary.

Unscrew spring cap from valve body.

Remove plug from detent housing. Push the detent stud in until the washer touches the coil oouslng. Grasp spacer with vise grips and remove nut from detent stud.

Grasp the sIX>Ol centering sprmgandpull spool from valve body. Then remove O-ring and O- ring retainer from spool.

To remove tbe centering spring. secure spool in a 80ft Jawed vise and install tbe . spring compressor lllustrated in Figure 1. Compress the spring and remove snap ring. Remove spring compressor from spring.

Remove spool gland. O-ring retainer and O-ring from valve body.

Remove the cover. washer and seal from the detent housing.

10. Loosen coll oousfng lock screw enough to allow the coll housing to be -removed. Remove the washer and coil rousing assembly. Be sure coil leads remain in

c I

I. 2. 3. 4.

SPOOL CAP SNAP R11IG SPIUNG SEAT . SPACER

6. O-RING RETAINER 7.

O*RIHG

SPOOL

GlAND

ISl SSI

5. CENTERING SPRING

Figure 11 - Clam Spool

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'.~.,j

400'1=14

Main Relief Valve 1.

seat from the seat sleeve unless it is to be replaced,

Unscrew the main relief valve cartrtdge from the valv-e oody. Then pull cartridge from valve body. Figure 12.

'Disassemble the relief val ve cartridge. a.

,Remove poppet spring and poppet from valve body.

8crew.

Remove plug from oPJXlstte end of valve .body and remove the drain sleeve and lIeat sleeve from the relief valve bore. Then remove the O-ring from the plug and O - ring and backup ring from the seat sleeve. Do not remove the poppet

.. r

Remove the scorn nut and loosen the lock nut. Then remove the adjusting

Remove the seal washers from the adjusting screw.

Remove the spring and pilot plunger from the relief valve cartridge. Do Dot remove the plunger seat unless it is to be replaced.

~/,

I~a

•

~.#~).

13 ~-:1I /"A,12

o <>

l. %. 3. 4. 5.

ACORH HUl

u.mtIOOE

\/ASHER

G-RlftG

LOC~

NUT

ADJUST I.... SCWI PLUNGER SPRING

6. PILOT PLlIHGER

10.

11.

•

12.

POPPET

eACKUP R,fIG

14.

PLUG

15.

DRAIN SlEEVE

POPI'£T SPRING

16. SEAT SLEEVE

PILOT PLUNGER SEAT

13.

POPP£T SEAT

Figw'e 12 - Main Reller-Valve

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4007-15

Secondary Relief Valve

bore, Do not remove the poppet seat unless it is to be replaced.

A secondary relief valve is located at the A and B ports of the bucket spool. 1.

Remove the relief valve assembly from the valve body.

Remove the spring and load check poppet from the valve bore. U both check: poppets are removed, keep them separate: so they will be installed in the proper

Disassemble the relief valve.

Remove plug and sbim(s) from the cartridge.

Remove the spring guide. spring and poppet from the cartridge.

Do not remove the poppet seat unless

it is to be replaced.

I. 2.

PlI.G O-RlN6

l. 4.

SHIM{S).SPRIHS GUll)[

S. 6.

IACIOJP lUNG; SPRUI6

8. 9. 10. 11.

POf'PET POPPET SEAT CAlffRIDG£ lMD OIECK POPP£T lOAD CllECK POPPET

su.r

Figure 13 - Secondary Relief Valve

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400.7-16 .

load Check Valves Load check valves are located at the A and B ports of the lift and clam spools. To remove a check valve. unscrew cap and re-

move spring and poppet from the valve bore, Do not remove the poppet seat Wlless it is to be replaced. Identify poppets so they wUl be returned to their respective bores.

•

2. J.

VALVE CAP O-RING

••

BACKUP RING

SPRING LOAD ~ECk POPPET POPPtr stAT

Figure 14 - Load Check Valve

Plugs and Fittings

Black

(18.7198 - 18.7220 mm) Blue " , •• , . , . 0.73710" - 0.73719" (18.7223 - 18.7246 rom) Yellow • , • • • • •• 0.73720" - 0,73729" (18.7249 - 18.7272 rom) Green ••••...• 0.73730" - 0.73740" (18.7274 - 18.7299 mm.)

Remove the power beyond fitting and any remaining plUgs !.rom the valve body.

Inspection 1.

Discard all O-rings and clean the remaining parts in cleaning solvent. inspect spool glands and wipers for wear and replace as required. Inspect the valve spool bores for grooves, deep scratches and excessive wear. Check to see that the spools fit their respective bores. Light hand pressure should be required to lnstall the spool and there should be no noticeable side clearance alter the spool Is installed. Inspect the spool lands fordeepscratches or excessive wear. Valve spools may be replaced if there is no damage to the spool bores. The lift and clam spools are coded to identify size and type of spool as follows:

•••.•••• 0.73700" - 0;73709"

(

The letter code stamped on the eye of the spool identifies type. D double acting and F float. When ordertng replacement spools be sure to include the oolor and type

codes. SJXlois are shipped with the centering spring installed.

I. TYPICAl. SPOOl. Z. SPOOl. TYP( COO( LmER 3. COLOR COOE

Figure 15 - Spool Code 4,

Inspect the load check valve and secondary relief valve poppets and the poppet

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4007-17

.eats for grooves, nicks aDd wear, Small nlcka and grooves oan be removed from the poppet and seat wtth a fine grinding compound. Lap sufficiently to remove the

Load Check Valve 1.

defect. Thoroughly waah the valve body

Pr~. ~ew

poppet seat Into valve body 11

seat was removed..

and poppet In cleaning solvent to remove all traces of grinding oompound.

Place check poppet and spring in the proper bore.

Inspect the mam relief valve plunger and poppet, and their respecUve seats fur ridges. nlck..s. etc. Replace parts as re-

Install backup rings and new O-rings OIl the cap and screw cap mto valve body unW Ugbt.

gulred if worD or damaged.

Secondary Relief Valve 6,

mspect all springs for sIgns of cracking and distortion. If sprtng tesling equipml!lDt 18 avaUable, obeck springs to see -U they meet the specUicaUons ilated on page 4007-3. If in (bubt about spring oondlUon. replace the spring.

Press new poppet seat Into valve body wu removed. Then place load cbeck. poppet and spring in valve bore.

If seat

,Make sure all tools and 'NOrk bench Lre clean before starting to assemble the control

Assemble the relief valve.

Press in new poppet seat 1f seat was removed.

Install poppet. spring and spring guide in valve.

Place shims on sprIng guide and Install plu," Use as many shims as

val ...

LubrIcate spools, spool bores and a-rinp with clean oU to &.ld in assembly.

were removed.

I. 2. 3. (. 5. 6.

PUJG O-RIH& SHIM{S) Sl'R'''' CU1Df WIW' RING SPIlllIG

,. ""'"

I. 9. 10. II.

POPf'ET SEAT WT1t.IDliE LOAD tllECk POPPET LOAD DEn POPPET YAT

Figure.16 - Secondary Relief Valve

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4007-18 3,

Install backup rings and new O-rfngs on reuet valve and install in valve body. Alter the control valve ta assembled. check the pressure setting as instructed I.n Section 4002.

Assemble the relief valve cartridge.

a. b.

Main Relief Valve 1.

Press new pUot plunger lIeat into cartridge l! the lIeat wa.a removed.

Place the pUot plunger and spr.ing in cartridge.

Press new poppet seat I.nto seat sleeve if seat was removed.

•

InsWl backup ring and new D-rinCon the seat sleeve, Then .install t.be seat sleeve and draJn sleeve in the valve body, Pusb the draJn sleeve into valve body untU tv.o or three tb.rea.ds are visible, tbeo screw plug wltb new D-ring into valve body, The seat sleeve Is now properly

Screw adjusting acrew into cartridge. Then ln8Wl eeal waSher, lock nut, seal wsaber aDd acorn nut. Do DOt tighten parte on adfusttDg screw at this time.

Install backup rings and new D-rings 00 the cartridge and screw cartridge Into valve body untU Ugbt..

positioned.

6, 3,

Plaoe poppet and spring in relief valve bore.

Check and adjust relief valve settlng as instructed 10 Section 4002 atter tbe control valve 18 Installed.

2. 1.

.t. S. I.

ACOIIft rM' IMSHEII JNI NUT ~STIHC

7. S. SCR(II

Pltll&£l1 SPRING PIlOT PLltI&EII

9. HI. U.

WTRID6l O-aIMG BAO:IJP IU. PILOT Plll&ll SEAT POPPET SJlttIIi6

12.

13. 1.. IS.

16.

POPPET I'OP1'ET SEAT PLUG DAAIN Sl£IY[

SEAT 5t.EM

Figure 17 - Main Relief Valve

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4001-19

S~RI NG

SNAP RI~G SPRUIG ~ EAT SPACrR CENHRIIIG SPRIII6

4. 5.

tAP

ro.

e-~[fIIG R""'I~ÂŁ11

.. ....., 7.

!l_RING

~POQ.

'!ISS'

Figure 18 - Clam Spool

Clam Spool 1.

Install centering spring If sprlng was removed.

Bucket Spool 1.

Secure spool in a 80tt jawed vise and place ~pr1ng and spring seats on spool.

Secure spool in a soft Jawed vue and plaoe spring and spring seats on spool.

Compress spring with compressor lllustrated tn Figure 1 and install snap ring.

Compress sprlng with co mpressor illustrated In F igure 1. Screw spring screw into spool and tighten with plIers or vise grips. Use care not to disto rt end of screw.

Install O-rL'1g retainer and new O-ring on aprlnlt end of spool.

Carefully slide sJX>Ol into Its bore. Uee care not to damage O-ring at spring end of spool.

Screw spring cap Into valve body and torque to 23- 25 foot-pounds (31-34 N m ).

Install centering spring 11" spring was removed,

Install new O- ring at eye end of spool. Work O-ring Into groove formed by the spool and valve body. Then install O-ring reta.iner and glund. Tighten gland with wr ench illustrated In Figure 1.

If detent a8sembly was not disassembled proceed to s tep 8,

mstall O-ring on connector and install

connector in detent hoUSing. Secure connecto r in place with lock nut and install the remB..1ning lock nut. 4..

lIutall the spRCer/wRsher / detent stud assembly In detent housing,

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•

4007-20

•

. ...

<:v " 16

11 .~

•

2. 7.

••S. ••

""" O-RING RETAINER O-RIf~G

s""-

SPRING SEAT CENTERING SPRING

7• SPACER SPRING SCREW LINK 10 . ROU PIN ». SPRING CAP lOCK IfIJT

••

...

13. D£TEh'T HOUSING

...".".". l4.

COVER IlASHER

".".

21.

SPACER MASHER COIL HOUSIJro

24. 25.

'"'lUG

22. om 23 • OETfNT STUD

S£At

COIL iIOUSlliG LOCK SCRDI C(»oINECTOR

7~IS56

Figure 19 - Bucket Spool

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â&#x20AC;˘ 5.

4007-21

Install coil musiDg .nembly .In detent bowling with coU toward the plug erad. Start ooU leads through the housing.

Torque cap to 23-26 foot-pounds (31M N m), T1&btEll the detent housing lock nut and measure the epace be-

PuSh 0011 housing into detent houaJng tnaking sure co11 leads rema.1D in slot in bowaing.

tWMD t.ba valTe body and detst hous-

ing: it should measure 2-11 / 16" (68,3 mm). Turn the connector into the spring cap to obt&in th1a dimflls10n and check: for pl"Optir ~itlon u previously instructed.

Align 0011 hoUSing with lock screw and

ttpten screw, TbeD tnstall seal, washer and oover. 7.

Install WUber on detent stud ancJ secure in place with nul Flab detent stud Into musing, grasp spacer with vise grips and tighten nul

Place spring cap over spring and secure cap in viae with the spool borUontBl. Be carefu1l not to dlatort the spring cap,

15. Install new O-ring at eye end of spool. Work O-ring into groove formed by Spool and valve body. Then instaUO-ring retainer and gland. TJptEm gland with wrench illustrated In F igure l.

Lift Spool 1,

Install cecteriDg spring on apoolif spring removed.

WIJI

Have somBOn8 available to help install tbe detect assembly. Push spool J.oto spring cap and detent stud .Into boWling to expose the roll pin bole 1D the link: and spacer. Allgn roll pin boles and install roll pin.

Secure spool in a. soft Jawed vise and place inner spring seat. spring and outer spr ing seat on the spool.

10. Screw oonnector m10 sprmg cap several lum.. and tlghten lock nut.

Compress spring with spring compressor Ulustrated in Figure 1.

Coat detent stud threads with 271 (red) Lectlte and screw atud into spool. Torque sbld to 9-10 !oot-

11. Install a-riDg retainer and new O-ring OD spring end of spool.

'JDunds (12-14 N

12. C&refully slide spool Into tW bore. Use Cll"e not to damage O-ring at spring ad of spool.

mJ.

Install outer O-ring retainer, amalIO.D. tirat, on sprmg end of spool. batall Dring retaJner and install O-rings a.ro\.Uld the lar~ 0.0.

Grasp the cetttering spring and carefully slide the spool into its bore. Use care not to dama'p O-ring at spring ead of spool.

NOTa: l! litt spool baa not bes removed Pl'Qceed to step 14.

13. Screw spring cap into valve body and torque to 23-25 !oot-poWlds (31-34 N m). Me~urt!l the space between the valve body and deteat bousfng; it should be 2-11/16" (68. 3 rom), LoosEIl spring cap lock nut and tum OOQnector into cap to obtain uu. dimeo.ion. Then loosen detent housing lock nut several turns and position housing coil leads toward the main relie! valve,

N m ).

Install detent washer in the detent housing. Make sure wuher is seated agaiDat shoulder in bousiDg.

Drop tbe steal balls (8) Into the bousJng aroUDd the detent stud. Apply a liberal aJDOWlt o! ,rcuc to the dotCIDt oam aDd install cam hl boustng.

wok

14. 1.oosen the spring cap nut and loosen the detent housing lock nut s~ veral turns. Hold detent bousiug &0 ooil leads are toward the maJn relief valve and acrew spring cap into valve 00dy.

Screw detent housing into valve body and torque to 23-25 foot-pounds (31-34

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4007-22

~' '110 , 9 ,

PLUG

10.

INN ER O_RING RETAINER

DEHNT SPRING DETENT CAM STEEt BALLS ( 8 )

11.

SPOOl SLEEVE GLA!UI

3. 4.

5. 6.

DETENT WASHER D£TOO HDUSI!iG SPOOl.

6. OUTER 9.

12. 13. 14. 15.

D·~rNG

O-RING

WIP£R WIPER RETAINER SP1t1NG SEAT

16. CENTERING SPRING 11. OETENT snJD

RETAINER

Figure 20 - Lift Spool 7,

Install detent spring and screw the adjustment plug into detent housing untU fl ush with housing, Adjust detent feel as required after the control valve has been installed.

Install new wiper in spool gland and press wiper retainer into gland. Then install O-ring in gland bore.

Install sleeve. small diameter first. over the spool. InstallO-ringingrooveformed by the sleeve and valve body and screw gland into valve body until it bottoms.

Start a mounting bolt with flat washer through a bushing and place a flat washer and s pacer on the bolt. Push bolt through valve moWlting hole and install a flat washer. lock washer and nut, Do not tighten nut at this time. Install the remaining flat washers and spacers in the same manner, then tighten all nuts.

Connect cylinder hoses and tubes to control valve fittings . Then tighten 11ft cylinder tube clamp on frame.

Ins tall the two outlet tubes and connect inlet hose to tee fitting.

Connect control linkage to the valve spools and connect detent wires to wir ing harness.

Start engine and run at low idle, Operate all cylinders through several complete cycles to bleed air from the circuits.

Stop engine and check for leaks, Check reservoir oil level and add a U as required.

Plugs and Fittings Install new O- rings on the power beyond fitting and plugs and install in valve body.

Installation 1.

Check to see that the metal sleeves remained in the rubber bushings.

Engage oontrol valve with tubes and tem-

porarUy install a mounting bolt and nut.

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Section

4034 THREE-POINT HITCH CONTROL VALVE

JICase A Tenneco Company

C, E. Div. 9- 66015 February 1976

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4034-2

•

TABLE OF CONTENTS Specifications . • . . . . . . • . . . . . . . . . . • • • • • • . . . • . • • • • • 4

••••••••••••

4034-3

General . • . . . . . . . • . . . . . . • • • • . . . . • . . . • • • . • . • . • • • • . . • . . . . . . . . . . 4034-4

(

Operation ........•••••••••••••.••••••.•.•.•••..•••••••...•.. 4034-4 Exploded Views . . . . . • • . . . . . . . . . . . • . . . . . • • • • . . . . • • • • . . . . . . . . . • . 4034-6

Inlet section . • . . . . . . • . . • . . . • . • • • . • • • • • • • . . . • . . . • . • . . . . • • • . 4034-6 Lift Section ......•.•..•....•..••••.••••••••••••••••.•••... 4034-7 Implement. Pitch. and Tilt SectionS ••••••.•••••••••....•.••.•..... 4034-8 Servicing the Control Valve ••••••••••.••••••.••.•••••••••.•••••••• 4034-9 ReIDOVal • • • • • . . • • • • • • . • • • . • • • • . . • • • • • • • • • • • • • • • • • • • • • . • • • 4034-9

Disassembling the Valve ....•••......•.••••••..•.•••.•••.•••.• 4034-9 Inlet Section . . . . . . . . . . . . . . . • . • • • • • • • • • • . • • • • • . • . • • . . . . . . . . 4034-9 Pitch. Tilt, and

~lement

Sections

~ _1 . . . . . . . . . •. . . . . . . . . .• .

. .. . . . . . 4034-10

LIft Section . . . . . . . . . . . . . . . • . . . . . • . • . . . • . . . . . . . • • • . • . . . . • . 4034-10

Assembling the Valve .•..•.••••••••••••••.••••••••••••••.••. 4034-12 Installation . . . . . . . . . . . . . . . . • . . . • • • • • • • . • . . • . . • • . . • . .

.••• 4034-12

~, .

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•

4034-3

SPECIFICATIONS

DescrlpUon • • • . . . . • . . . . . . . . . . . . . . • Four-spool directional control valve consIsting of six sections shown in Figure 1. Three paraliel passages in working sections carry 011 to and from cylinders. Orifice plate at inlet restricts 011 flow

to maximum cyUnder requirements. Compensating spool in Wet section regulates oU flow as follows: first priority to cylinders. excess to reservoir through outlet port. Also see pages 4034-4 to 4034-5. ReUef valves Main relief valve Type . . . • • • • • . . . • . . . . • • • • • • • • •

CartrIdge type. direct acting. adjustable Setting . . . . . . . . . . . . . . . . . . . . . . -:-. . . . . . . . . . 1800 !. 50 pst at full throttle (12 410:!:. 344 kPa at full throttle)

Secondary reUef valve, lift section

Type . . . . . . . • • • • • • . . • • • • • . • • • • . • Cartridge type, direct acting. adjustable Setting . . . . . . . . . • • • • . . . . . . . . . . . Hand pump setting. 1900 psI (IS 100 kPa) Ports and Spools Spool tr ave I Neutral to pressure • . . . • . . . . . • " • • . . . . • . . • . . . . . . . . . • . 5/16" (8 rom) Neutral to float .....•••••••••.•••.•••..••••••••••• 19/32" (15 rom) Spool movement into valve body . . . . . . . . . • • • • . . • • . . . . . . Pressurizes porl A Spool movement out of valve body • • • . . . . . . . . . . . • . • • • • .• Pressurizes porl B Service specifications Tie rod nut torque . . • • • . . . . . . • . • . • . 28 foot-pounds. lubricated with 011 (38 N m) Springs Centering. all but 11ft spool ...••••••••.•••.••....•• 1-1/4" at 15 pounds (31.8 nun at 6.8 kg) Centering.ll!t spool •..••••••••••••.•.•...••.••. 1-17/32" at 15 pounds (38.8 mm at 6. B kg) IJft spool detent • • • • • . . . • . . . . . . • . . . • . . • . • • • • • • . • 21/32" at 5 pounds (16.66 mID at 2.3 kg) Plunger . • . • • • • . . . . • . • • • • • • • • . • . . . . . . . . • • . . • • 1-1/4" at 14 pounds .. (31.8 rom at 6.3 kg) Spool . . . . . . . . . . . . . . . _ • .• ••••••...•.•••••••••... 1-1/8" at 6 pounds ~ (28.6 nun at 2.7 kg)

"" """,--1"

RElIEF

• r.

Figure 1 - Control Valve

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â&#x20AC;˘

4034-4

GENERAL The valve Is a pressure compensated directional control valve consIsting of six sections as'1011ows: an lnlet secttoncontainIng the outlet, inlet, flow regulator, restrictor, and main rellef valve; three sections for the tnt, pitch, and ~lement cylinders with a three-position spool In each; one section for the 11ft cyl1.Dderwitb. afour-positionspool; and an end section.

Tbe three positions avallable at all spools .are power at A port, neutral, and power at B port. In addition, the lift spool has a fourth position, Float Down. In FloatDown, the spool is mechanically held (detented)untll manually released. The spools are returned . to neutral from the power posItions by centering springs.

OPERATION Flow Regulation Flow from the inlet section to the cylinders passes through a fixed orifIce which prevents oversupplying the cylinders. The compensating spool regulates !low on apriortty basis--the cylinder being operated receives oll lirst with the excess (if any) returned to the reservoir.

At the same tlme, the spool (7) opens passages which allow the pump supply to flow thrOUgh the or1f1ce plate (5), and load cbeck poppet (8) into the closed end of the cylinder (11) caUSing the cylinder to extend.

Note that the shift of the compensating spool (4) opens the pump supply to the outlet passage. Excesspump supply flows through the outlet -port to the reservoir (10).

The pressure created by the cylinder (11) movement is transmitted via grooves in the valve face to 'the pilot paesage to the tq:l of the co~ensat1ng spool (4).

This pUotpressure acts aga.tnsttbe ritnof the compensating spool and the floating plunger causing the plunger to bottom out in the bore of the compensating spool.

'lbese forces, added to tension of the spring, shift the cottq)ensating spool downward against pump pressure at the opposite end of the spool. As conditions of supply, resistance, and demand change In the system, the spool Is reShifted as requtred.

To explain the remaining valve co~Â nents and their function, we will describe a typical operating sequence.

Operating Sequence Refer to Figure 2. 1.

The pump (1) is operating at normal speed.

The operator pulls a control lever moving the spool (7) into the valve body.

Pump supply flows thrOUgh the Wet port of the inlet section.

Pump 011 flows through a small bole in the compensating spool (4) fllllng cbamber. This causes the compensating spool to sbift upward against the tension of spring on top of spool. As the spool Shifts, the floating plunger slides down to compensate for the 011 displaced by the shift of the co~ensating spool.

A check ball (not shown) prevents movement of oU In the light red colored passage toward the spool (7). NOT.:

10. If the cylinder (11) cannot move, the main reilef valve (8) opens at 1800 psi and vents oU to the reservoIr (10). ~ 11.

'When the operator returns the spool to neutral, the compensating spool (4) shifts fully upward and the entire pump supply flows to the outlet port.

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4034 -5

â&#x20AC;¢ SUCTION OIL . PUMP FLOW PILOT PRESSURE RETURN OIL

PUMP

2. INLET SECTION

3. MAI N RELIEF VALVE 4. COt~PE NSA TING SPOOL

5. O~IFICE PLATE 6. WORKING SECTION 7. SPOOL 8. LOAD CHECK POPPET

9. PILOT PASSAGE 10. RESERVOIR 11. TYPICAL CYLINDER 751 SO

Figure 2 - Operation of Three-Point Hitch Control Valve

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•• •

4034-6

EXPLODED VIEWS

I~ ·8 lOG

\I!

. i'

•

(

•"

••

l ,

•

( '

I. PLUG 2. O-RlltG

6. IlASH£R

1. ORiFiCE PlAT[

1. COMP£HSATI"G SPOOL 4. PLUNG£R SPRI/fG

8. SPOOL SPRIIIG

9. CHECX

Y~LYE

SPRING

10. CHEa:: BAll II. ORiFICE SCROI

12. ~IK REtiEF CARTRIDGE 13. HOOSING 'S156ot

5. PLlINGER

F igure 3 - E xploded View of Inle t Section

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...

4034-7

~" ~,:

1. CAP SCREW e2l

2. 3. 4. 5.

OETEIIT CAP [l(l£NT IIOVSIH& WI' RIftS SPRING sur

6. C{NT[RIKa SPAIMG 7. OfTENT STlJD 8. O-RING

(

9. DETENT CN1 10. DElOO SPRING

17. 8OTTOM O-RING RETAIH£R

12. POPPET SPRING

18. IfOOSJN6 19. SCREW 20. WIPfR RETAI/lEII:

14. SPIXl.

21. .... IPER 12. TOP O-RING RETAINER

11. BAll RETAIKER

13. LOAD CHECK POPPET

15. SP'-'CER

16. SPOOL EYE

23.

SECOH~Y

RELIEF VALVE

Flgure 4. - Exploded Vtew of. Lift Section

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•

1. 2. 3. 4, S.

CAP SCREII (2) SPItiNG CAP SPRING RET"IHING SClIEl/ Oo-R1NG SPRING SEAT

6. cnntRIH& SPl:IH6

1. S. 9. 10.

POPP£T Sl'Rtlll lCWl QlECK JIOPp[f SPOIl. SPOIl.. m

11. WIPER RETAINER 12. WIPER 13. SCREII 14. HIlUSIIIG

Figure 5 - Exploded View o! In:pletnenl, PItcb and Tnt Sections

()

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..• INJECTOR TEST STAND Fuel inj.ctors must be checked on the test stand when perlonning the followine ..rvice operationa: 1. Whenever an injector has been ,."oved from the angine fOf' c ..anlng. the Injector must be checked on the teat stand prior to installine it on tha engine.

2. When a new Injector auembly is to be inmliM. it must be checked on the teat mnd prior to Installing it on the angine.

3. When a complete engine o .... rh.ul ta perfOf'An

"Approved" Injector Ten Stand. C ...

Part No. M20322 (Bach.rach No. 65·93401. 'I required for testing and adju.-.:lng the injec.-

mM. the injectors should be remo ....d .nd checked on the test mnd.

tora and can be purchased through the Service

4. When an injac vr is suspected to be the C8UU

Part. Supply, J. I. Ca.. Co., Racine. Wi.c.

of unsatisfactory eneine perlormance. it should be ntmOV'8d from the cytlnclar hAd .nd checked on the teat stand prior to dis....mbling it.

Ellcept

for

descriptions

referring

••peclally

to adjustment. on the tnt atIInd i!Mlf. all of the following instructionl will apply to all mtlk... Operating instructlon. are al.o furnished with ttte test stand. An Jnjector tool kit, ea.. Part No. M10520 (Bacharach No. 60-oo10J. ia required to ..,vice the Injectors. A compression "auge adapt ..., BtK:harach No. 70-314 (D-Se;8) • al.o Included in the tool kit. This kit ia uHd in conjunction with the Case DieHl Tool Kita, Cue Part No. M20247 (CD-BOO) and C... Part No. M20241 (CD·36DI.

IMPORTANT: ALWAYS CHECK THE PER. FORMANCE OF AN INJECTOR ON THE TEST STAND BEFORE DISASSEMBUNG IT. IF IT CHECKS OUT SAnSFACTORILY, THERE IS NO NEED TO DISASSEMBLE OR AQ.JUST IT.

Preparing Test Stand 1. After filling the teat .tand fuel ,...rvotr, 1000n the bleeder screw.

The tnt mnd is used to perform the follow-

ing check.: , . Ch.ck and adjust the injfH:tor 0...,1"" pressure. This is • duplicate of the factory pro-

cedure.

2. Check the injector assembly for fuel leakage.

'7.:. When the fuel flowing from the bleeder screw opening is free of bubb..s. dghWn

....

.i,

3. Wash the connector tuba. and adapter in cle.n diaM' fult!. Blow clean with filt..-.d comprea.nd air .nd connect HCurely to the test stand.

3. Check and adjust the injector leak-off.

4.0per.. the hand· laver slowly until ct.n fuel flows frOm the .dapter. 5. The test stand is now ready for u ... NOTE: Complete operation and maintenance instructions are fumished with the test ttand. Follow the instructions carefully.

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•

3OL'l-1'

•

TESTING INJECTORS Prior to testing

injector.

remove

the

kw.. carbon from the tip with an injector cl.aning brush. Cle.n the carbon seal groove and body betow the groove in the .. me man· n.... IMPORTANT: 00 not scrape or brush

Do not attempt to connect the injector inlet fitting direct:y to 8 standard Ermeto or 600 lIWaged type line as damage to the tubing Qn rel.Ult .

the Teflon coating above the CIIrbon ... 1

Checking Opening Pressure

groove.

Clo.. the

p~HUre gauge valve and flu'" the in;.ctor by operating the tnt pump repidly. Open the gauge and rai .. the pre.ure slowly until the injector v:Jve open•. (The gauge read· ing will drop sharply .t this point). Check open·

ing pressure again.t the specification',

NOTE: When tuting mOf'e than one injector out of the engine, the,. mUI1 not be more than 100 PSI diffeNnc. between any of tM injectors in that engine. If the injectors do not meet the specified opening pressure;

Uaing the test pump adapter eacharacfl Part

No. 65·878, connect the injector with the tip

f.e;"g downward. TEST PUMP ADAPTER 815·878 (N491

1 . N_ injectors c.n be adjulted to the specifi.cI opening preuure. See P.ge 22 .

2.lnjectorl that do not check out on the test ltand Ihould be disassembled and cleaned. See Pages 16 thru 21. -3. Valve lift screw may be out of adjustment. See Page 22.

4 . Chectl: for broken or weak opening pntSlUre control spring. Me specifications.

Checking Seat Leakage ~oint the injector tip down and operate the test pump rapidly to firmly seat the valve. Dry the injector tip thoroughly. Raise the preuure at the injector 200-300 PSI undet' the specified opening pressure. A drop aho lei not form on the tip within 10 seconds. Slight dampness. however. is permissable with • used injector. If drops fonn on the injector tip. the following should be done.

1 . Di.....mble and clean injector. page. 16 thru 21 . 2 . Valve is not free in guid.. Lap valve to guid •. See pagel 18 & 19. 3 . lnsp.ct for pitted or cracked valve tiP. eroded valve seat or pitted and distorted body. These conditions require replt!cement of the complet. inj«:tor ....mbly.

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4034-9

SERVICING TttE CONTROL VALVE Removal

Inlet Section

Disassembly

accumulated dirt and . grease from the valve and surrounding area to prevent entry of dirt into the hydraulic

Remove

Refer to FIgure 3.

system.

Remove plugs from top and bottom of valve. Remove parts shown in Figure 3.

Use an Allen wrench to remove the _ o.rifice screw.

Remove the reUef valve cartridge and O-ring.

Lower the bitch fully or rest in:Jplement (if attached) on the ground. With the

engine Shut off. move each control lever back and forth to relieve circuit pres-

sures. 3.

4. 5.

Before removing the valve,

tag and num-

ber the hoses that connect to the valve. starting at the 1nlet section. Number the top -port of the inlet section No.1; the bottom port No.2: the top port of the implement section No.3, etc. ~ . Disconnect hoses and closeopeningswitb. clean caplugs. ~-

On the tractor, connect the pump supply hose to the rerum 11ne. NOTE:

Inspection 1.

Inspect the compensating spool and plunger for scoring. burrs. and excessive wear. Make sure spool orifice is open. Ii spool or plunger require replacement. the complete section must be replaced.

Inspect 'the housing for cracks. Sbine a light in the spool bore and check for scoring and wear. If the hOUSing must be replaced. replace the complete section.

Check the spool spring compression with a suitable spring testing device. Replace spring if it does Dot meet specification

-,.

Do not start the engine without

completing step 5. 6.

Remove the control lever pins frol!l the

valve spools.

OD ~age 4034-3. -~.'"\'I

Remove three mounting bolts and lockwashers. Carry the control valve~ to a _clean work bench for disassembly.

The rel1efvalve maybedlsassembledfor inSP~CtiOD ~ cleaning. Check the plunger and 'seat. If the relief valve is damaged inany way. replace the entire relief valve.

Replace O-r1ngs.

NOTE: Cleanliness is very Impork'!lt.. Service this control valve in the cleanest surroundings possible. F

;~,

Disassembling the Valve 1.

Starting at the inlet end, number all the sections to assure reassembly in the original position. ....

orifice' screw is open. '

Remove three tie rod nuts at the inlet section. Slide sections off the. tie rods as

...-required. . ,

.Remove the three a-rings from the face oreach section and inspect for damage. Take care not to lose the two steel balls from the face of each section (lift. tut pitch, implement).

Replace the steel ball and orifice screw If damaged. Make sure the orifice in the

Clean all parts in solvent and dry beIore reassembly.

Assembty

~bricate .. a-rings

Assemble parts sbown in Figure 3. Lubricate spool and plunger with hydraulic oil before installation.

with -hydraulic oU.

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•

-4:034-10

Pitch, Tih, and Implement Sections

Assembly

Disassembly

Lubricate hydraulic centering grease or

Clamp the spool in the vise used durlng disassembly. Assemble the centering spring, poppets, and spool eye as shown in Figure 5.

lnsla.U wiper retainer, wiper, small dia-

Refer to Figure 5. 1.

RelDOve two spring cap cap screws. Remove the spring cap and wiper retainer.

Pull1he spool assembly out of the valve.

Clamp the spool In a SOFT jawed vtseor between wood or brass strips.

Unscrew the centering spring reWnlng screw. This will permtt removal of all parts from the cap end of the spool.

meter tow&rd retainer, and new O-ring on spring eod of spool. 4.

Lubricate spool and spool bore with hydraulic 011 and tnsWl spool in valve section using care not to damage O-ring. Secure spool in place with spring cap.

Install Dew O-ring in groove formed by the spool and valve section III eye end of spool. Install wiper. largo dhuneter first. over a-ring. Then Instull wiper retainer.

NOT.I Poppets must be returned to their original position. If reused. 5,

Unscrew tile spool eye. Remove tile J)q)J)et and spring from the !!!pool.

Remove remaining wiper retainer. Remove wiper and O-ring from each end of the spool bore.

Inspection

seals and internal parte with 011 before assembly. Coat the spring and spring guides witb bydrwllc 011.

Uft Section Disassembly

Do not Intermix spools and sections. Always return a spool to Its original NO~1

section. If either the spool or housing must be replaced. the oomplett, section must be replaced.

Refer to Figure •. 1.

Remove two long capscrew& which reWn the detent assembly.

Clean the metal parts in solvent and dry with moisture free compressed air.

Replace check poppets if worn or damaged. Replace wipers and O-rings.

Pull the spool assembly out of the valve.

Inspect the valve body and spool for

SUde the O-ring retainer and detent assembly off the spool. Use care not to lose the four detent balls.

Remove the centering spring:

grooves, deep scratcbes, and excessive wear. See that the spool slides in and out with a. ellghtband pressure and without noticeable sJde clearance.

Remove the detent housing cop and detent hOUSing.

a. 4.

lD~ct

the machlned faces of the sectlooe for nicks and burrs. Use a fine oll stone, working with light rotary motioD. to remove anynicke and burrs. Thoroughly waab the valve section lncleaningsolvent to remove all traces of grit.

The centering spring must be compressed to remove the snap ring. Fabricate a pair 01 compressor plates, Figure 6, or use the compressor suppl1ed with Case Kit No. 045700. Co~re"s the spr1ng8 as shown.

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40S4-11 6.

the spool in a SOFT ja'IWd vise or

In.pection

between wood or brua stripll.

1. 7.

Uoscrew the detent stud and 'Pool.ye.

'-j

card the wipers and O-rings.

I-j----,----j j-

\ t -t4t--r F~OM

COLD

~OLlED

STEU

2. J. 4. 5. 6.

1/8' (3.2 "") 2·l/r (635 ... 1 1-1/2' (38 1 ... 1 l-1I 4" (31 8 II1II) 3/." (19.1 .... ) 11/16" (llS "",i

5/16' DIA. (7.9_J

Inspect the parts in the detent assembly SlId replace worn or damaged part&. Test the !!pring with a suitable spring tester--tt Should compress at the rate specified on page 4034-3.

Inspect the machined faces of the section for nicks and burrs. Remove any nicks and burrs with a fioe 011 stone, work::l.ng

13/16" (20.6 II1II)

11/16" (l7.5_J 8OTTOM PlATE ISISI?

Figure 6 - Compre68or Plates

Inspeot the valve body and spool Cor

T:)P PLATE

.Replace poppets if worn. or damaged.

grooves, deep scratches, and excessive "''ear. See that the spool aUdee In am out with slight hand pressure and wtthou.t noticoable side clearanoa. If either the spool or houSing must be replaced, replace the enUre section.

IIAK£ llI(l '1£C£5

1-. MAU

I ,

)

Clean the meW parts in solvent and dry '\Io1tb. moisture free compressed air. 018-

with a light rotary motion. Wuh the 88C-

tion in cleaning solvent to remove all

tracea at grtt. 6.

The reUef valve may.;)8 dJsassembledfor in.8pection and cleaning. Check the plunger and seal If the relief valve fa damaged in any way, replace theentlrerelJef valve, If reUef valve W9J5 disassembled and Is to be used again. Cheek: pressure setting as instructed in Section 4002.

1l1iTl

Sl'OOl

COMPR(~~OR

&tH. T AIIO ,.,.

~T£

•. sw i. i.

'WIG SJI'IIIIIG

Assembly

~EII

Figure 7 - Compressor Spring

----e:-

ReDlOve poppet -and $perms frem

1. both~~

ends of the spool.

NOT.: Poppets must be returned to their original position, 1! reusefl.

lubricate seals and internal parts with fLYdxaulic aU before assembly. Coat !be centering t!prtne and ~t &8&embU""e.~_ 'IV1th grease or hydraulic all. Clamp the spool iD the viae used during dil!J48sembly.

lnBtall the check poppet.

and springs, spool eye, and detent stud, 9.

Flgure 4.

Remove the remaining retaiDer from the valve body,

10. Remove the rellef valve cartridge.

.....ssemble the ceoterLng spring and IIPring

seats over

detent stud. Compress the

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4034-12 centering spring. Figure 7. and install the snap ring.

section and install the O-rings and !lteel balls.

Install the seal retainer with O-rings and wiper at the spool eye end of the valve housing.

Assemble the remaining sections in the numbered order until all six sections are stacked up.

Assemble the detent meChanism parts and seal retainer on the spool. Use grease if required to retain the steel balls.

Lubricate the spool with hydraulic 011. Slide the spool into the valve housing. Take care not to damage wiper and.seals.

Install the tie rods and nuts. Lubricate the threads on the end of the tie rods and the bosses on the end section 'WhIch bear against the nuts. Torque the tie rod nuts evenly to 28 foot-pounds (38 N m).

Installation

Install the detent housing cap and hYo long capscrews.

Mount the valve on the bracket with three bolts and lockwaShers.

Install the relief valve cartridge and O-ring.

Connect control lever l1nkage.

If fittings were removed. be sure the restrlctor flWngs are installed in the upper (A ports) of the tilt, pitch and lift: sections. Connect bose to valve. A hydraulIc diagram showingproper connecting poJ.nts is 10 Section 4002.

Assembling the Valve Refer to Figure 1. 1.

wbricate new O-rings with hydr311l1coU and install in the grooves on the faces of

â&#x20AC;˘

.u the

setting of the matn reltefvalve was

disturbed, perform the pressure check

the valve sections.

and adjustment, Section 4002.

Clamp the inlet section (tagged no. 1) in a vise with the machined face pointIng up.

Install greased O-rings, andor1ficeplate on the face of the inlet section.

Stack the implement section on the inlet

If the setting of the relief valve in the Hit section was dis'b..trbed, perform the pressure check and adjustment, Section 4002. NOTa:

Replacement rel1ef valves are

preset.

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Section 4090 CYLINDERS

J I Case

A Tenneco Company

C . E. Dlv. 9- 66015

February 1976

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4090-2

•

TABLE OF CONTENTS

. . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

4090- 3

Spanner Wrencb Set . . . . . . . . . . . . . . . . . . . . . . ........•.......... . .

4090-4

All Loader. 3 Point Hitch and Backhoe Dipper. Bucket and Stabilizer CyUnders . . . . • . .. .. • • . . . . • . . . •.•...•.•. • . . . • . . . . •

4090-5

Removal • • .••••...•. . • .. ..• . .••..•• • •. • • • ..•. . •.•. .. •• . •

4090- 5

Disassembly . . . . . • . . . ... • .. . . • . • • •• • •• .. • . . . .•• • • . ••• . . . .

4090 - 6

Inspection . . . . . . • • • .. . • . • . . . . . . • . . . • • . • . . . . •. . . . . • .. . . . . .

4090- 6

Assembly . . . . . . . . . . . . . • . . . . . • . . . . . . . • • . . • . . . . . . . . • • . . .•.

4090-8

Specifications

· . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 4090-9 Swing Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 4090- 10 Removal . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 4090-10 installation

Disassembly

., .... . ... . .......... . . , . . ........ .. .. . ... . 4090-1 0

....... , ... , ....... .. . .

4090- 12

Assembly . , • . . . . . . . . •••• • ..• •.•• ••••• •. • . ••• .. .. ... •• . .

4090- 12

Inspection

... . ..... .. .. .. .. . ...

.. Boom Cylinder · . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal , .. ..... ..... ..... ..... . . .. ...... . .. ..... . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly · . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . , . . . . Installation · . . . . . . . . . . . . . . . . , . . . . . . . . . , . . . . . . . . . . . . . . . . Installation

· . , . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . .. , "

4090- 13 4090- 14

l.J

4090- 14 4090-14 4090-14 4090-14 4090- 15

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~O-3

SPECIFICATIONS Piston Bolt Torque and Cylinder Weight

- Bolt Torque

Loader Cylinders

Weight (approx.)

Lift

415-525 ft-lbs (644-711 N m)

50 Ibs. (23 kg)

TUt Clam Grapple

200-220 tt-lbs (271-298 N m)

36" Ibs. (16 kg)

47&-626 ft-lba (644-711 N ID.)

200-220 tt-lbs (271-298 N m)

31 Ibs. (14 kg) 231bs. (10 kg)

475-525 fl-lt18 (644-111 N m) 1000-1200 ft-lbs (1356-1627 N m) 475--525 ft.-lbs (644-711 N m) 700-750 ft-lbs (949-1017 N m) 1000-1200 it-Ibs (1356-1627 N m) 200-220 tt-lbS (271-298 N m)

83 Ibs. (S8 kg) 101 lbe. (46 kg:) Bllbs. (3T kg) 58 Ibs. (26 kg) 701bs. (32 kg) 95lba. (43 kg)

Ttl.

.200-220 ft.-lbe (271-298 N m)

Lift

200-220 ft.-lbs (271-298 N m) 200-.220 ft-lba: (2'11-298 N m)

23 Ibs. (10.4 kg) 291bs. (13 kg) 24 lb., (lO.9 kg)

Backhoe Cylinders Boom Dlppt1r

Bucket

Swhg stabilizer Extst.8ion

3 Point Hitch Cylinders

Pitch

o ,

la.

•

p ..-

•

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4090-4

Hydraulic Fittings (Stael) Dash

Size

Tube 0.0. Hose 1.0.

Thread Size

37· FlaT;! Torque Ft-Ibs

Straight Thread O-ring Torque

N m

Ft-Ibs

•

1/4"

7/ 16"-20

6-12

S-16

12-19

16-25

5/ 16"

1/2".20

S-IS

11-21

16-25

22-33

3/8"

9/ 1S"-18

10-25

14-33

25-40

34-54

1/2"

3/4"-16

15--42

20-56

42-67

57-90

5/S"

7/8"- 14

25-58

34-78

58-92

79-124

3/4"

1-1 / 1S".12

40-S0

54-lOS

SO-12S

108-174

7/S"

\.3/16"-12

60·100

81-135

100- 160

136-216

1-5/16"-12

75-U7

102-158

117-187

159-253

1-1/4"

1.5/8"-12

125-165

169-223

165-264

224-367

1-1/2"

1·7/8"- 12

210·250

25S-338

250-400

339-642 160l!~

C SPANNER WRENCH SET Spaner wrench set, part DO, 044110 contains the necessary wrenches to remove and install glands on Case manufactured

cylinders. The wrench set is ava1labletbrougb Service Parts Supply.

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4090-5

6,, )

ALL LOADER CYLINDERS, 3 POINT HITCH CYLINDERS AND BACKHOE DIPPER, BUCKET, EXTENSION AND STABILIZER CYLINDERS Removal 1.

StabUlzer cylinders. Lower stabilizer to the floor. Disoonnecl hoses at tubes on cylinder. Remove pivot pins and remove cylinder.

Raise loader arm slightly above hood level and blOCk bl place USing a suitable support UDder the bucket or loader arm Crossmember.

Rest the loader bucket on the .ooor. Position the backhoe as required to

allow easy access to the cylinder heJng removed. Provide support for the back:boe to prevent it from collapsing when

hoses are disconnected or the cylinder is removed.

Remove the 11ft cylinder rod eye pivot pins. Have someone available to prevent the cylinder from falling when the pin is removed.

Remove accumulated dirt from cylinder and bose or tube fittings before diaoonoectlng llnee. As lines are daoonnected,

close all open.lngs with clean caplugs. 3.

With the engine stopped, move the cylinders oontrol lever in both directions to equalize circuit pressures.

If chain hoist can be used, attacb holst to bucket and lower bucket to

Note the welgbt of tho oylinder being

If cba.in boist cannot be used. reinstall the rod eye pin and lower the bucket to the floor. Then remove the pinlS.

the floor.

removed on page 4090-3 and have lifting equipment or additional help available as required to prevent personal injury or unnecessary damage.

Disconnect boses at manifold tubelS on mside of loader frame. Remove oylinder from pivot pin.

Remove the cylinder.

Dipper cylinder. DJ.soonnect mae at tube to rod Emd of oylinder. ReIDGve

Loader bucket cyUndel'. Disconnect Cl'OS8 hoses at swivel connections. Remove rod eye pivot pin. Remove inner cylinder mounting Hllk and remove cylinder.

Clam cylinder, DiscolUlect hoses at oylinder. Remove pivot pin retaiD.lng bolts and remove pivot pins and cylinder.

Three point hitch cylmders. Provide support tor hltcb as r~uired. DiBoonnect hoses at cylinder. Remove pivot pins and remove cylinder.

ho.e olamp inside the boom and re-

move cylinder pivot ptns. Disconnect bose at closed end of cylinder.

Backroe buoket cylinder. U equipped standard dipper. disconnect hoses at tubes OD boom. Remove cylinder pivot pins and remove oylinder. U equipped with an exteD.dable dIpper. dIsconnect hoses at the cylImler. with

Slrtenslon cylinder. Refer to Section 9100 and remove dipper extension, then the cylinder.

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4090-6

Disassembly 1.

Secure cylinder in a vise using care not

to distort the tube. Remove the self-tapping acre....' ÂŁrom the gland. Use a spanner wrench and unscrew gland, Figure 1.

1. PROTECT ROD WITH CLOTH 2. CLAMP ACROSS ROD EYE

Figure 2 - Removing Highly Torqued Piston Bolt

Inspection

1. SPANNER WRENCH

Wash parts .In cleaning solvent and dry with moisture free compressed air.

Discard piston packing (vee rings), 0rings. backup rings, seal, wiper and other parts found to be excessively

Figure 1 - Removing Gland

WO~.

Carefully pull the piston rod from the cylinder. Pull the rod straight out to prevent damage to the cylinder wall.

Secure piston rod eye in a vise as SID\IItl in FIgure 2 and remove pIston bolt. Bolt torque .ranges from 200 to 1200 footpounds (271-1627 N m).

Shine a lIght into the cylinder tube. If it bas deep grooves or score marks, or bas been severely damaged in any way, it sbould be replaced.

Inspect piston rod for aUgnme:nt. Replace if bent; do not attempt to straighten.

Inspect bushings or bearings and replace as required.

Before assembling the cylinder. remove any minor nicks, scratches, etc. on the rod or in the cylinder tube with a medlum grit emery cloth. Polish with a rotary motion rather than lengthwise.

Scoring, pitting, etc. aresignsofpossible oil contamination. Check hydraullcoU for contamination,

Remove piston assembly from piston rod. Pull pIston halves apart and remove the center ring. vee rings and end rlngsirom the piston halves. HOTS:

1f disassembling three point

hitch pitch cylinder with one piece piston. remove wear ring, Teflon plstlon ring and O-ring.

Remove gland from piston rod. 1f necessary, the gland may be driven off the rod with a soft hammer. Refer to Figure 3 and disassemble gland.

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6.-

.....,

4090-7

, I

GOa

c@,

.. ,

8t1~1~~~ RHAIN£EA'.,,,, 50' 'YHtHG 8

SOME RODS HAVE

PISTotI I'\QO

10.

5. G.

~~~p

ll.

SEAl

"i:\,,",

••

WIPER I£AAING

SElt·cr

7. 8.

)2.

"'" Figure 3

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4090-8 •

Assembly 1.

Refer to Figure 3 and usemble gland.. The U-cup rod seal may be ve.y dllficult to insWl. Use as much care as possible Dot to cut the seal lips. Use a blunt tool. preferably wood or plastlc. to push seal into place. Make sure seal lips are to tbe Ins ide. NOTa: If a new gland 18 being installed. stamp the cylinder part number on tbe face of the new gland.

Place center ring on ODe of the assembled platon halves and fit the halves together.

If assembling a dJpper cylinder or st&bUizer cylinder, apply a light coat of Amojell petroleum jelly (or equivalent) to the following surfaces: bolt threads. bolt washer surface. boths1desofwasber and end of piston rod.

Secure pIston rod eye in a viae and su~ port platon end.. Place platon assembly on rod and installplaton bolt wlthwasber. Torque p18ton bolt to specifications on page 4090-3.

Secure piston rod eye in a vise and lubricate the gland bore and rod with clean bydraul1c oil. Install gland on rod. If necessary, the gland may be driven onto the rod with a soft hammer.

Lubricate the vee rings with clean bydraullc oU. Position an end ring and three vee rmgs on each piston balf, Figure 4. If one of tile three rings 1s of a dllferent composition, make sure rings ue installed as illustrated in Figure 4. If u sembling a three point hitch cylinder with one piece piston, install a-ring. Teflon piston ring and wear ring on piston. N0T81

1. CLAMP ACROSS ROD EYE 2. TORQUE TO SPECIFICATION ON PAGE

4090-3

Figure 5 - TOrquing Piston Bolt (High Torque)

••

ISUI'

Figure 4 - Vee Rlna: lllstallation

Secure the cylinder tube in a vise and througbly lubricate the cylinder wall and pLston packJng with clean bydraullc 011. Install the pl..ston rod straight into the tube. After the pistoD bas started into the smooth portion of the tube, screw the gland into the b.1be but do not tigbten . The piston rod can now be worked farther IDto the tube with a rod through the rod eye or a soft hammer.

Torque the gland untll the sell-tapping screw boles in the gland and cylinder line up. Then install self-tapping acrew. Gland torque sbould be betweeo 100 and 200 foot-pounds (135-271 N m). NOTa:

II a Dew gland or blbe 18 balD,

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.090-9 used, drill a Dew bolefortbese1f.tapping aarew after the gland baa beeutorquedto 100-200 foot-poWlds (13$-211 N m). Ve-

lD, a No. 26 (3.7338 mm) drill, drill the bole half in the gland and half 10 the cylinder approximately 5/16" (1.9 mm) deep. Do not drill in Unewitht.be spanner wrench boles.

Torque bose and tube conn8Ctions to specifications in Sectlon 1051.

Lubricate cylinder pivot points with grease specified in SecUon 1050.

Start engine and run at low Idle. Operate the cylinder(s) through several cycles to bleed air from the circuits. Do not "bottom out" the cylinder(s) untll the cyllnder(s) mov~ smoothly and without besUation. After the cylinder La fUled with aU, engine speed may be increased and the cyllnder(8) may be operated normally.

Stop engine and cbeck for leak•• Check reservoir oU level and _de all u required.

Installation 1.

All cyIJnders can be metalled by reversing the removal procedure on page 4090-5.

It is suggested that one end or the oylinder be anchored and then oonnoct hoses and/o r tubes. U bose or tube connecting points were not identified. refer to the appropriate secUon in the 90 Series to assure proper connectioos.

Start engine and run at low 1dle. Slowly move the cylinder'. oontrol lever to extend or retract the pLaton rod as required to align loose end of cyll1lder with Its mounting point.

•

()

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4090-}0 SWING CYLINDER

Removal 1.

Rest backb:>e bucket on the floor .

Remove accumulated dirt from cylinders, boses and !lttin~.

Disconnect ooses to right hand cylinder at tube at top of mainframe and closed end of left hand cylinder.

Disconnect ooses to left hand cyllnder at closed end of l"ight band cylinder and the rema1nJng bose at a convenient swivel connecting point.

Remove rod eye pin retaining plate on bottom of swing tower and drive pin out.

Remove the trunnion plate. Remove the four mounting bolts with nuts and hardened washers. The bolts are torqued to

1. SPANNER WRENCH Figure 6 - RemOving Gland

020-640 foot-pounds (705-667 Nm). Then remove cylinder from mamirame.

Disassembly 1.

Secure cylinder i'l a vise using care not to distort the cylinder. Use a spanner wrench and UllIJCreW gland. Figure

S. 2.

Carefully pull the piston rod from the cylinder. Pull rod straight out to prevent damage to the cylinder wall.

Secure piston l"od eye in a vise and support piston end as shown In Figure 7 and remove piston bolt. The bolt 1s torqued to 700-750 foot-pounds (ln9-101? N m) and will require consIderable force to loosen.

Remove restrktor pin from bolt or piston rod. Then reIlXlve spring and spacer from piston rod.

Remove piston from piston rod. Then pull piston halves apart and remove the

1. PROTECT ROD WITH CLOTH

2. CLAMP ACROSS ROD EYE Figure 7 _ Removing Piston Bolt center ring, vee rings and end rings from piston halves,

Remove gland from piston rod. If necessary, the gland may be driven off the rod with a soft hammer. Refer to Figure 8 and disassemble gland.

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•

4090-11

,. »

ani

." ,-

• 23

•>

• •

•

,.,L

BIJSH!/fG PISTON ROD

..... ,.

.-,-,e-

•• to_

WIPER

SURING

U-CUP SlAl ilACKOP RING

(l-RlNG

PISTON BOLT

""'''

11. RESTRICTOR 12. SPRING 11. SPA(£lt

..,,-

>S.

...". lB_

ro_ 'lUG

HAlf

IIINER Plsr:n END RING VEE R~~~NG

PI5TO" HALF

'L ,,-

SJIIIING GO! """ ...". "0< =5[,11T

D£

23-

CYliNDER'PING SCltOl SElf-TA

Figure 8 - Swin g Cyllnder

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4090- 12

Remove relIef valve from closed end of oylinder. If the rellef valve bas an Allen head plug, the intemai parts are serviceable. However, do not disassemble the valve unless 1t 18 suspect (jarring or extremely spongy stops). II the relief valve baa .. hex bead plug. tbe valve Is serviced as an assembly only.

Remove elbow from closed end of cylinder and remove flow restrictor from cyUnder.

In.pection Refer to page 4090-6.

Assembly 1.

1. 2.

Refer to Figure 8 and assemble the gland. The U - cup rod seal may be very dIffIcult to install. Use as much oare as possIble not to cut the seal Ups. Use a blunt tool . preferably VIOOd or plastic . to push seal into place. Make sure seal lips are to the inside.

END RING NTlO!( RING

K(OPII(NE ~ING CENTER ~ING

lin"

Figure 9 - Vee Ring Installat ion

NOT.: II a new gland Is being installed. stamp the cylinder part number on the face of the new gland.

Secure piston rod eye in aviseandlubrlcate the gland bore and rod with clean hydraulic oU . Install gland on rod. If necessary. the gland may be driven onto the rod wIth a soft hammer.

Luhricate the vee rings with clean hydraulic oU. Two of the three vee rings are of a dlfferent composUion and must be installed on the piston halves as illustrated in Figure 9. Place an end ring and vee rings On each piston half.

1. CLAMP ACROSS ROD EYE 2. TORQUE TO SPECIFICATION ON PAGE

Place center ring on one of the assembled piston halves and fit the halves together.

Place the spacer In bolt Mle in piston rod and place piston assembly on rod.

Place washer on piston bolt. Install restrictor pin in piston bolt, tapered end first , and place spring on pin. Screw bolt aa usembled Into pIston rod and torque to 700-750 foot-pounds (949- 1017 N m).

4090-3 Figure 10 - Torquing Piston Bolt Secure cylinder tube in a. vise and tho-

roughly lubricate the cyliDder wall and piston packing with clean hydraulic oU.

Install the piston straIght Into the tube. After the piston has started into the smooth portion of the tube, screw gland into tube but do not tighten. The piston rod can DOW be worked farlber into the tube with a rod tbrough the rod eye or a soft hammer. 8.

Torque the gland until the sBlf-tapping screw ooles In the gland and cyUndel'

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4090-13 line up, Gland torque should be between

Installation

100 and 200 foot-pounds (135-271 N m).

1. If a new gland or tube is being used, drUl a new hole for the self-tapping screw after the gland bas been torqued to 100-200 foot-pounds (135-271 N m). Using a No. 26 (3.7338 mm) drill, drUl the hole half in the gland and half in the cylinder approximately 5/16" (7.9

NOTa:

Position cylinder in maJnframe and secure in place with trunnion plate. Make sure hardeced washers are used between bolt and trunnion plate, andnutandmainframe. Torque trunnion plate mounting bolts to 520-640 foot-pounds (705-867 N m).

mm) deep. Do not drill in Une with the

spanner wrench holes. 9.

PosItion rod eye I.n swing tower and install pIvot pin. Make sure retaining plate groove is to the center of the swing tower and drive pin in from bottom of swing tower. Secure pivot pins in place with retaining plate.

Connect hoses

lAlbricate the cylinder pivots with No.2 moly disulfide grease.

start engine and ron at low idle. Operate the cylinders through several complete cycles to bleed air from the circuit. After the cylinder has been filled,6Ilglne speed may be increased.

Stop engine and check for leaks. Check reservoir oll level and add oU as r~ quired,

If '-be relief valve was .disassembled, refer to Figure 8 and assemble valve, H parts were satisfactory and jarring stops were noted duriDg operation, remove one or tw'o shims. If stop was extremely spongy, add one or two shims.

10, Install relief valve in closed end of cylinder. Be sure new O-rings andba.ckup rJng have been installed on the valve

to cylinder and tubes and/or control valve. Torqueconnectlons to specl1icatloDs in Section 1051.

body.

11. mstall now restrictor in port in closed end of cylinder. Restrictor must be installed small end first. Then install the 90Âˇ elbow. N~: Two diff'erellt restrlctors are used and can be identified by restrictor bole diameter as follows:

WIth Extendahoe . .. .125" (3.17 mm) Witrout Extendahoe . . 126" (3.96 mm)

(

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•

"090-14

•

BOOM CYLINDER

Removal 1.

Completely retract the dipper and bucket and lower boom 50 buCket rests on the floor. Move boom control lever in both directions to equalize circuit pressures .

Remove th~ cylinder piV'Ot pin rela..inIng bolts and nuts. Disconnect hoses atcylmder and close openings with clean caplugs.

Have li.fU.ng equipment or another person ava.llable to aid In removlngthecylinder. Remove the pivot pin at closed end of cylinder. Then work cylinder off the rod eye pin. If necessary. remove pin retaining ba.rdwa.rd on eye end of opposite cylinder and drive pin out of rod eye.

Disassembly Secure cylinder In a vise using care not to dUstort th~ l.:ylJ.ndcr. Use & spanoer Wl"enoh and unscrew gland. Figure 11.

-.-

Secure piston rod eye in a vise and support piston end as sbo~n in Figure 12 and remove pl.eton bolt.

1. PROTECT ROD WITH CLOTH

FIgure 12 - Removing Piston Bolt

Remove pistDn from piston rod. Thea separate piston hal ves. Remove the vee rings and adapter rings from the outer piston half. Remove wear rini from inner piston halL

Remove gland from pl..stoo rod. If necessary. the gland may be drIven off the rod with a soft. hammer. Refer to Figure 14 and disassemble gland.

;

Inspection Refer to page 4090-6.

Assembly 1.

1. SPANNER WRENCH

FIgure 11 - Removing Gland 2.

Carefully pull the plston rod from the cylinder. Pull rod straight out to prevent damage to the cylinder waH.

ReIer to Figure 14 and assemble the gland. The U-cup seal may be very dlJ£1ouU- f.g....J,a.tall IIae as much care u possible not to cut the seal lips. Use a blunt tool. preferably wood or plastic. and push seal into place. Make sure seal lips are to the inside. U a new gland is being installed. stamp the cylinder part Dumber on the face of the new gland. NOTe::

( 1

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, 2.

4090-15 After the piston baa started Into the smooth portion of the tube. screw tho gland into the tube but 00 not UghtEll.

Secure pullan rod eye lD a vise and lubrioate rod and giand oore with clean hydrlluUo oil. In.tall gland on rod. If

oecea8ary. the gland may be driven onto the rod with a soft bammer. 3.

Lubricate the vee rings with clean hydraulic oU , Two ot the three vee rings ue of a ditferent composition and must

The piston

rod

can now be worked

farther into the tube with a rod through the rod eye or a. soft. hammer.

be installed as Wuatrated in Figure 13.

Install the vee rings and adapter rmgs on the outer piston half a.a illuatrated

Torque the gland uoW the self-tapping screw boles in the gland and cylinder line up. Oland torque sbollid be between. 100 and 20() foot-pounds (135-271 N m).

Nor.: 11 a new gland or tube 11 beJng

in Figure 13.

AMPTER ImlG

N[(I~RENE

used, drW a new bole lor the self-tapping screw after the gland bu been torqued to 100 - 200 foot-pounds (13~ 271 N m). Ua1ng a No. 28 (3.7338 mm) drUl, drill hal! in the gland and half in the cylinder approximately 5/16" (7.9 mm) deep. Do not drill in line with the

l. Itn.ore

4 • QUT[R' I SHill HALF

spanner wrench holes.

In.tau.tion

- .....

Attach piaton rod eye to its phot pJn. Make sure tlat washer 11 installed b&tween the boom and rod eye•

•,

Place outer piston half on piaton rod.. Then install washer and inner pl8ton hall 011 piston bolt and screw bolt Into piston rod. Torque bolt to specification on page 4090-3.

Align closed end of cylinder with IIlO\DlUng ear on swing tower and install pivot pin. Make sure bale in p1n and cylinder yoke are Jined up before installing pin. Secure both pins In place with nut and boll

Cormect boaea to cylinder.

Start engine and run at low rcD.e. Operate tbe boom through several complete cyoles to hleed air from the circuits. After the oylinder has f1lled, engine speed may be increased.

Stop engine and check !or leaks. Cbeck Tesenoir oU level and add oU as required.

15I~1

'\.,'l

Figure 13 - Vee 8,Ild Adapter Ring Installation

Jnatall new wear ring on inner platon

halL 6.

SeoUl"t! cylinder tub. In a vise and thorougbly lubricate the cyilDder -wall and platen packing with clean hydraullo oU. Install the pilton straight Into the tube.

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4090-16

I. 2.

PISTON II IPER

BEARING

4. 5.

GLAND U·CUP SEAL

ROQ

BAC~UP

7. 8.

O-RING PISTON BOLT

9. 10.

RING

WASH£R WEAR RING

11. 12. 13. 14. 15.

INNER PISTON fl~U ADAPTER RINGS OUTER ~ISTON ~AlF V~E A~D

CY lI ~D(R

SELF-TAPPING SCREW

Figure 14 - Boom Cylinder

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Section 4107 BACKHOE CONTROL VALVE

J I Case A Tenneco Company

C. E. Div. 9-66015 February 1976

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4107-2

•

TABLE OF CONTENTS SpecUlcations . . . • . • • . • . . . . . . . . . . . . . . . . . . . . . • . . • . . • • • • • • • • • . . • 4107-3 Special Tools . . . . • . . . . . • . • • • . . . . . . • . • . • . • • .. • . . . . • • • . . .•..••• 4107-4 General • . . . . _ . . • • . . . . • • • . • . • . . . • . . • . . • • . . . . . . . . . . . • . . . . . . .. 4107 .... Operation

• . . • . . . . .. .. • • . . . . . . . • • • • • . . . .• . • . • • • • • • • • . • • . . . . . 4107-6

OU Flow, Dipper Spool Actuated . . . . . • • . . • . • • • . . . • • ...•••. .. •..•. 4107-6

Regeneration . . . . . . . . . . . . • . . . •• ...•. . . . . • . . . . . • • • • . . . . . • . . 4107-6 Secondary Relief Valves , Boom, Dipper and Bucket Sections •.....••.••••• 4107-6 Secondary Relief Valves and AnUcavitaUon Valves, Swing Section ••••••••••• 4107-6

Servicing the Control Valve • . . • . . • . . . . .. . . . . . . • .. .. .•.••••••..•••

4107-16

Removal ..••. . • . . . . . , . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .

4107-16

Disassembly of Control Valve •••... ...•.••. ••••••••.•. .• •• ... • 4107-16 Disassembly and Assembly of OUtlet Section . . . . . • • • • • . • . • . . . . . . . . . . 4107-16 Disassembly and Assembly of Inlet Section •... . .•. ... ••••••••••.•.

4107-16

Disassembly of Working Sections . . . . . .. . . . . • . • . • . • . . • • • • • . . . . .• 4107-17 Inspection of Working Sections

..•...•••••••.•..•.....••.•.•••. 4107-18

Assembly of Working SecUons

. . ..

. . . . . . . . . . . .. .. . . . . . . . . . . . . .

4107-18

Assembling Control Valve . . . . . . . . . . . . • ... • . •..•.•••••.•••...• 4107_18 Secondary Relief Valves . . . . • . . . . • . . . . . • • • . . • • . . . • • • • • • . • . . .• 4.107-22 Disassembly. . . . . . . • . • . . • • • • • . • . • . . . • • • • • . • • • • • • • • • . .•

4107-22

Inspection . .....•••••••• ..• .. .• . • • . . • • . • • . . . . . • . . • • . • .

4107-22

Aasembly .. . . . . . . . . . . . . . • . . . • . . . . . • . . . • ... ••..•••.... 4107-22 Checking and Adjusting Pressure Setting. . . • • . . . • . • • • . • • • • • • . •• 4107-22 blstallation . . • . . . . . . . . • • • • • • • . • . • . . . • . . . • • . • . • • • • . . • • • . ••

4107-28

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4107-3

SPECIFICATIONS Non; The following specU1cations and serv1ce information apply to control valve part numbers G348n and 036360. Too dif-

ference between the valve Is the added section in the G3S360 valve for the dipper extenaion.

Secondary relief valve pressure settings . . . . • • • . . . . . • Relief valves .... 111 bave pressure setting stamped on bOdy. Th1B fiaure lndicates the nominal setting at full £low and should be disregarded when checking presaure setting. Refer to Section 4002 for specificatloo.s and test procedures. Main relief valve pressure setting . .. . . . . . . . . . . . . • . Refer to loader control valve ma.ID relief val ve setting in Section 4002. Ports and spools Spool travel, neutral to pressUl'e . . . . . . . • . • . • . . . . .. .4S" (11.4 mm) in and out ~'poOl in . . . . . . . . . • . . • . • . . . . . • • • • • • • • . • • • • • . . . . . A port pressurized Spool out . . . . . . . . . . . . . . . • . . . . • . . . • . • . . . . . . . . • . .. B port pressurized Port threads, aU. . • . • . . • . •. . . . . . • . • •• •• . . . . • •• . . •• I-S/16"-12, O-ring Special torques Tie bolt nuts . . . . . . . . . . . . . . . . . ..• . . . . . . • . . . 20-30 foot-pounds (27-41 N m) Centerlng spring cap. . . . . • . • • • • • • • • • . . • . . • .. 20-30 foot-pounds (27-41 N m) Secondary relief valve cartridges . . . .. . . . . . . . . ..• 65-8S foot-pounds (85-11S N m) Secondary relief valve adjusting screw lock nut . . . . • • . . . . • • . . . . . . . . . . • . . . • SO-80 incb-pounds (5.6-9 N m) Check valve plug . • . . . . . . . . . . . . . . . . . . . •..•.. 65-85 toot-pounds (Sl)-l1:i N m) Springs Regeneration spool Inlet section cbeck valve Swing section anticavitation Load check valves Secondary relief valve Spool centering Weight (approx.) . . . . . ...•• .• ...•

Free length

Compressed length

2 .007" (53.26 mm) 2.04" (S1.8mm) 1.08S" (27.6 mm) .709" (18mm) 1.78S" (4S.3 mm) 2.27" (57.6 mm)

1.61" at 62 %4 Ibs. (41 mm at 28 U.8 kg) 1. 56" at .95 % 01 Ibs. (39.6mmat.43:k.OSkg) . 7S" at . 57::t: .04 Ibs. (19 mm at .026±.018 kg) .31" at .43::t:.04Ibs o (7.9 m.m at.2± .02 kg) l,S1" at 137:1:16 Ibs. (38.4 mm at 62:i: 7.2 5 kg) .87" at 3S::t:2.1Ibs. (22 mm at1S.9±1 kg) 95 JXlUDds (43 kg)

•

•••

••

••••••

•••

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4.107-4

•

SPECIAL TOOLS

lr--'--J==;,=:j' 1----.-----1 1.

1-5/8" (41. 3 ... ) 2 IIEQUIR£D

6. 7.

3/4" (19.1 11m) 1-112" (38 . 1 rTIII) 5/ 16" DIP.. (1.9 ""')

,. 5.

1/8" THICk (3 .ll!l'll) 1/8" DIA. (22.2""",) 1-1116' (27",") 2-lIS" (5 4 mil

I'\U£ TWO PIECES FRQoI COlD ROlLED STEEL

751600

Figure 1 Spring Compressor Plates

liS'· 16 • ]" ( 76 ... 1 DR LONGER IlEI aCII. T GRIllO M SIDES

Il.2

GRIND TO 1/8" -J 5/ S' 10.9 lin)

EVEKLY TO 15/32" ( 11.9 .. )

Men-.: Retainer plates, part number D26830, also can be used, See Figure 9.

Figure 2 Check Valve Plug Removal Tool

GENERAL Refer to Figure 3 and 4. The backhoe is an opeo center parallel passage control valve. The parallel passage starts at the fnlet SectJOD and dead ends at the regeneration sensing piston in the outlet section. OU displaced tram the cyl1ndere !lows to the ouUet section through the return passages at the top and bottom of the valve sections, The return 011 !lows to the outlet port past the regeneration spool. The function of the regeneratlon spool and check valve located in the inlet and outlet seetlen is discuued under Operation.

The design of the total loader /backhoe hydraulio sYliitem allows the main relief valve in the loader control vulve to protect all hydraulic c1ru1ts. Therefore, the backme control valve has no ma1n relief valve. Load oheck valves between the parallel passage and the work porte prevent reveres

!low of 011 between the cylinders and the

control valve as a spool is moved into a power poSition. Secondary relief valves are connected

to the A and B ports of all working sect.lons except the extension section to protect the individual circuits when a cyl1nder Is forced to move with the valve spool in Neutral. AnUcavitation valves are connected between the rebJ.rn passages and work ports in the Swing section to prevent voids in the swing cirouita. Control valve operation is discussed on page 4107~6. With all control valve spools in Neutral, oil from the pump !lows stra.1gbt through the open center passage to the outlet section and back to the reservoir.

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•

• 4.107-6

" l.

OUTLET

5_ SWlrtG SfCTlotI 6. IfUl S[CTIOH

~ECTIOH

2. SOOH SECTION 3. OlP~ER SECTIO"

10. REGOIWT1OH CJ![CK VALVE

11. SEC(»CMU R£LlEF VALVE 12. MICAVITAT!11I VALVE

7. A POIIT

BOCKET SECTIOI

REG[If£R.l.TIOH SPOOL

8 PORT

1SIDO

634897

1. 0UT1£T SECTION 2. tXTENSIO!II SECTI OII 3. 8(01 SECTION

4. DIPPER SECTION S. 8UtKrT SECTION

6. 7,

$VIII& SECTltlI tNl-ET SECTION

8. 9.

A PORT ,PORT

10.

11.

l'. 13', 14.

635360 Figure 3 - Backhoe Control Valve

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â&#x20AC;˘

4.107-6

â&#x20AC;˘

OPERATION Oil Flow. Dipper Spool Actuated Refer to Figure 8 which shows the dipper spool moved out of the valve body to move the dipper in and load the bucket. Moving the spool into the power position causes several simultaneous events: (1) the open center passage 18 blocked by the SPOOl. (2) the parallel passage Is charged with oll from the pump As pressure builds, the oU then flows past the load check valve to the B port of the dipper section and to the closed end of the dipper cylinder, pushing the dipper toward the macblne to load the bucket, (3) the A port Is connected to the upper return passage so oll displaced from the rod end of the dipper cyltnder can be returned to the reservoir. Because the parallel passage is connected to all working sections more than one spool can be actuated at the eame time. However, the cylinders(s) meetIng the least resistance will move first, When the spool is returned to Neutral, oil is locked between the cylinder(sl and spool _ preventing further movement of the cylinder(s),

Regeneration 011 dfsplaced from any of the cylinders can be diverted to the inlet section to supplement 011 from the pump. Regeneration occurs only wilen pressure in the parallel passage Is approxtmately 350 psi or less and a spool is actuated.

Refer to Figure 6. As an example, regeneration could occur us the bucket is being lowered into a trench. The weightofthe boom. dipper and bucket ....,ould have a tendency to pull the piston rods out of the boom cylinders, When this happens, pressure in the parallel passage drops to 350 psi or less and the spring under the regeneratJon spool in the outlet section moves the spool to block the return passage. The pressure created In the return passage opens the check valve in the inlet section and the 011 displaced from the rod end of the boom cylinders then supplements the pump flow, When pressure in the parallel passage rises to 350 psi or more, the sensing piston in the outlet sec-

tion pushes against the regeneration spool to open the return passage.

Secondary Relief Valves. Boom. Dipper and Bucket Sections Refer to Figure 8 whicb sbowa the dipper section actuated to push the dlpper toward tbe macb.tne to load the bucket. As the dipper Is moving it pushes the boom up which creates pressure in the closed end of the boom cylinders. When pressure In the boom cylinders 1s equal to the setting of tbe relief valve connected to the A port of the boom section, tbe relief valve opens and relieves oll and pressure to the return passage. The boom section was used u an example only; the relief valves in the dipper and bucket sections will function in the same manner if the cylinders are forced to move the valve spool in Neutral. NOTa: The low pressure settlng of the relief valve connected to the boom section A port also protects boom cylinder piston rods from being bent wben extended.

Secondary Relief and Anticavitation Valves. Swing Section Refer to Figure 7. Alter the swing spool bas been returned to Neutral to stop thesw1ng cycle the boom oontinues to move because of the momentum created during the swing cycle. The oontinued movement of the boom then creates presaure within the return circuit whicb forces the poppet 10 the relief valve connected to the B port off Us seat allowing oll and pressure to be relieved to the return passage. In addItion to protecting the circuit from damage, the relief valve prevents a jarring stop of the boom. At the same time, pressure In the re-

turn passage unseats the antlcavitation valve oonnected to the A port to prevent voids in the swing cirouit. Cavitation (voids or air pockets) occurs because of unequal movement of the piston rods in the swing cyllnders_ The anticavitatioll valves will also open during a powered swing if the pressure in the parallel passage is apprOXimately 350 psi or less. Refer to Regeneration on this page.

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4107-7

4107-8

, . IP UMP FLOW

2. RnURN 01

3. INLET 4 , SWING !i .. BUCKET II. DIPPE,R

FIgure 4 -

7 . BOOM

111 .. RETUflN PASSAGE

B .OUT....,li

112. A PORT

9'. OPEN DENTER pASSAGe (INTERNAL) PARALLElLPASSAGE !INTERNAt.1

114. R G NERATION SPOOL

11) ,

on Flo w Thl"Oug lt B cklloe Valve

In : eutraJ.

13. B PORI"

16. R EGE.NERA.1lI0N CHECK VAIL"Ve 16. SECONDARY RELIEF VALVE 17. LOAD CHECK VALVE 18 . A NTICAVI A"fIOI'!l VAlV

19. FROM PUMP viA l-OAOER ,C ONTROL AND STABILIZER CONTROL VALVE 20, RESERVOIR

VALV~

., .,

•

.....,,,ow

I. 100..

MU". . 00..

•. IT.no::_

o"".n

II 0"" C..... , .......... """"~"""

" 'u"........ Iua, ,_,."""", n", ... $ _ O~ 1'\0.. to . . ... _ ...

12tJ ...... ..,U.", U"',,"'"

................T"''' .......

...

,~.N

• ••"

I. _

.. _ " oU..""o.

......."".

. ' . _ ..... ' VIA 1.0..... CO ...UOL "A' YI ................ CO .... OI. ..... ""

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4107-10 11

· PUMP FLOW · RETURN OIL · STAne:: 01

4 . IN!.E 5 . SWING S. !llICKET 7 . DIPPER

8. BOOM 9 . OllTLET 10.. OPE N CENTER PASSAGE JINn'RNA!.1 11. PARALLE'b PASSAGE UNTERNALI

12. RETuRN PASSAGE 13. A PORT 14. B POIlT

15. REGENERATION SPOoL

16. 17. is. 19.

REGENER TloON SENSING P ISToON REGENERATIONI C~ECK VALV E S ECONDARY RELIEF VA.lvE LOAI) CHECK VALVE OPEN

20 . ROOM DOWN FlESTRICTOIl 21. FROM pUMP lilA. LOADER CONTROL VAlvE AND STABILIZER CONTRO L VALVE 22. RESERVOIR

.u07_11

,,---

.,•• m.

...'"

, ••

""M~

.<OW

~''NU n~nc

0"0"'

,, •,

U'UU •• • •:;~:j ~:~;~"::::':~: 1"''''u_U UO,"' """U " on 1.00_'' , Boom ood 11"",,«"100

1>. .~.u.C' 13." 'OR, W. 11'00, . . . EC'N<R"TlON ,~OO'

. .

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4107-12

4107-11

n 10

•• ~

.I! .; .;. :

~~>~>:~:

~~-~,j~

•

.e. 'f: ~

" Z1

1. PUMP FLOW .2 . RETURN OIL 3 . ST,I\nC OIL

4 . IN ef 5 . SWING 6 . BUCKET , . DipPER

Il. BOOM !I. CURET

10 . OPEN CIi'".TEFI PASSAGE (INTERNAL)

111. PARAllEL PASSAGE (l1'IIl'EIIIIIAU

Flgur 6 - Oll Flow . Lowering Boom and

12 . 13. 14. 1S,.

Reg~erati.on

RETURN PASSAGE A PORT B PORT REGENERATION spooa

UiL 1'. 18. 19.

REGENE.RATION SENSING PIS ON REGENERATION CHECK VALV opeN SECONDARV RELIEF VALVti LOAD CHKI( VALVE OpEN

20. DOOM DOWN RESTR ICTOR 2: 1.. FROM PUM P vIA LOADE II CO NTliIOL II.ALVi: AND STABIUZ:ER CONTROL VA.lIIE 22. RESERVOIR

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4107-13

4107-14

I 11

1. PUfoilP FLOW 2 . R ETUR N 'OIL

3. STATIC OIL -lOlL Â£MS9LACED FROM swING CVUND:ERS

5. 6. 7. II.

IN ET SWING aLlCKET DIPPER

9. BOOM

1!J.. 14. 11. OPEN CENTER PASSAGE UNTEAftfALI 15, 12 , PARALI.EL pASSAGE UI'iTERNAU 16,

10.0UTlJET

Figure 7 - Ou. Flow, Boom , \\'iinging to RigbJ. :Uid Stopping

II E'WR N PASSAGE A PORT B PORT REGENERATION SPOOL

nEGENERA.T10N SENSING PISTON 21. ANTICAVITATION VALVE 22. FROM PUMP VIA LOADER ,~ONT ROL VALVE 19, sECONDARV REI..IEF vALv E OpEN AND STABILIZER CONTRct VALVE zo. LOAD CHECK VAL VE Z3. ~E !!reRVOIR

'8. REGENERATlION CHECK vAl..vE

•

• "01_U

..••

_. I. PUM. ,'-OW • UT\lU Do.. ,_ nAnc a'L

•. I. ,.

• 0"' O' ....... C.D '00 .. ..,0," ""UNO'"

.11. ."""0" ""..,.

I. 100M "SA~' 10 . OlJT,-n t1. Q'<N CONTE • •ASS.OO , .. TI ........ '" • ",,1fT ,., •• q .... ........ PGOL II ........ U.I. .... I ... ~. , .. n.""1l

... ""OM DOW N .UTRICTO" n. 'RoM """', v .. LOAD •• CONTRa .. v .... " • COHT"Ol

.....0 STU'U".

n, ....."0'.

V.lV.

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4107-15

4107-16

1- PUMP Fl.OW :/: . ~ETURN OIl!. 3. STATIC OIl!. II. OIL DISPLACED FROM BOOM ,C YLINDERs

!i. o. ,. 8.

INLEl" g. SWING O. BuCKET 11. DIPPER 1<2.

BOOM OUTLET OPEN CENTER PASSAGE (INTERNAL! pARAt.LEL PASSAGE [lNTERNALJ

F'1gIl r e II - Oil Flow. Dipper CyUnder Extec.dmg. Boom Section ReHef Valve Open

13. RET'UIIN PASS.AGE

14. A PO T 15. B POR 16. REGENERA,. 01'11 SPOOL

1'1. REGEN ERATION SENSING PISrON 18. REGEN RATION CHECK VA LVE 19. SECONDARY IR EI.IEF VAlViE OPEl\! 20. ' OAD C'HECK VALVE OPEN

21 , BOOM o.OWN R eSTRICHI H 22 . FHUM PUMP VIA LOAD ER CONTHOl VALVE AND STABlUZER CONTIlOL VALVE 23 . RESERVOIR

â&#x20AC;˘ 4107-16

SERVICING THE CONTROL VALVE Disassembly and Assembly of Outlet Section

Removal NOTE.: Tbecontrol valve weights approximately 95 pounds (43 kg). Use care in handling valve to prevent personal lnjuryordamage to the valve. 1.

SWing backhoe to the right or left. Place backhoe in transport position and install the cunning lock pin or oompletely retract the bucket and dipper and lower boom untll bucket rest on the floor. Move all control levers in both directions to equalize circuit pressures. Then

Refer to Figure 12 and remove regeneration spool plug.

Remove spring, regeneration sJX>OI and piston. The sJX>OI is held by the fit of an O-ring.

Remove O-ring from groove in sJX>Ol bore and plug, and discard.

If spring testing equipment is available, check spring against specification on page 4107-3. Also c beck spring for distortion and signs of cracking. Replace spring If either condition Is evident or It does not meet the specification.

Check sJX>OI and piston for nicks and

dlsconnect control linkage at the valve spools. 3. 4.

Remove tube between the stabUizer valve outlet and the backhoe control valve inlet. Remove grease fittings from top swing oylinder trunnions. Place a piece ofl/2" plywood or a. metal plate on top of the trunnIon bracket and under the control valve. Secure front end of plywood or plate to swing cylinder rods.

Disconnect hoses and tubes at control valve. Loosen tube clamps as required and plaoe tubes out of way so control valve can be removed through opening in the main frame. Cap or plug hoses and tubes.

Remove control valve mountlng nuts, washers and bolts and remove oontrol valve from main frame.

burrs that may cause them to stick in their bores. Use crocus cloth to remove defects.

Cap control valve fittings and remove accumulated dirt from valve if this has not been done.

Place control valve on a clean work surface. Starting at the inlet section. number the working sections to assure proper assembly.

Remove nuts from Ue bolts and remove valve sections. Remove and discard all O-rings and keep shims for use during assembly.

Install new O-ring on plug and in groove. in spool OOre.

I 7.

Install piston and regeneration spool in outlet section. Place spring in spool and secure parts In place with plug.

Disassembly and Assembly of Inlet Section 1.

Refer to Figure 12 and remove check valve plug. Then remove sprLng and poppet.

Inspect poppet seat in the Inlet sectlon. The seat Is pressed ioto the inlet section; do not attempt to remove unless U is to be replaced. Minor defects can be removed using lapping compound. Clean inlet section thoroughly to be sure all traces of grit has been removed.

To replace the valve seat:

Disassembly of Control Valve 1.

â&#x20AC;˘

Place the valve section on a drill press. The section must be se-..a. cured in a suitable fixture. ,.,

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4107-17 b.

Use a 21/32" (16.7 mm) drUl and

drill the length 11/32" (8.7 mm) of the seat. NOT.: Use care when drilling. If the bore in which the seat is installed Is damaged in any way. the valve section must be replaced.

d. 4.

SPOOL SPRING Stt.AP RIHG 026830 RETAINER PLATE OR SHOP MADE PlATES

8()lT AND IfUT

After drilling, a thin shell will remain. Remove this shell and wash the valve section in cleaning solvent. Be absolutely certain that all traces of metal are removed.

751599

.Press the new seat, chamfered end first, into the bore until it bothorns,

Figure 9 - Removing Centering Spring assembling the boom section. mark relief valve in top of boom section to assure proper assembly.

Check spring for distortion and signs of cracking. If spring testing equipment is

avallable, check spring against specification on page 4107-3. 6. 5.

1. Z. 3.

Install new O-ring on plug and place

poppet and spring in valve section. Secure parts in place witb plug.

Using the tool illustrated in Figure 2. remove the load check valve plug. Place tool in slot and twist to engage notches in plug. Pull straight up to remove. The plug is held by the fit of the O-ring.

Disassembly of Working Sections NOTE: If more than one section is to be disassembled, identify the parts as they are removed to assure they will install in the proper section during assembly.

Refer to Figure 13 or 14 and unscrew spring cap. The cap 18 torqued to 20-30 foot-pounds (27-41 :w m).

Grasp centering spring and pull spool from valve section.

Remove the wiper and O-ring from top of spool bore. and O-ring from bottom of bore if It was not removed willi the spool.

Remove the centering as shown in Figure 9. Compress spring with shopmade plates or Case supplied retainer plates. Figure 9. Remove snap ring. release spring tension and remove parts from spool. Remove the secondary relief val ve cartridges. The cartridges are torqued to 65-85 foot-pounds (85-115 _N m). If dis-

SHOP /\AOE TOOL

2. CHECK VALVE PLUG 3.

O- RING l! UOO

Figure 10 - Check Valve Plug Removal 7.

Remove the load check valves and springs. The parts will fall out of the valve.

Swing section only: Refer to Figure 14 and remove --the two plugs on the rear. Remove the anticavltatlon valves and springs.

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4107-18 valve plug on special tool and install plug. Push plug down until it bottoms. Then p:>sition plug so slot p:>ints toward the spool. Install the remaining valve, spring and plug in the same manner.

Inspection of Working Sections 1.

Discard all O-rings and replace with new parts.

Clean parts in cleaning solvent and dry with moisture free compressed air.

Install the secondary relief valve cartridges using new O-rings and 'torque to 65-85 foot-p:>unds (85-115 N m). If assembling the boom section, make sure the relief valve stamped 1000 or marked during disassembly is installed in tbe top.af the valve section.

Install new O-ring in groove at top of spool bore. Then press or drive in wiper, lip to the outside. In recess at top of spool bore unW it bottoms.

Place new O-ring and the a-ring retainer on spring end of spool. Secure spool in a soft jawed vise and place centering spring and spring guides on spool. Compress sprlng as instructed under disassembly and secure parts in place with snap ring.

Lubricate sp:>ol md spool bore with cle8J1 hydraulic oil and install spool from bottom of valve section.

Install spring cap md torque to 20-30 foot-pounds (27-41 N m).

Swing section only: Refer to Figure 14 8J1d place anticavitation valves and springs in bores on rear of valve. hIstall new O-rings on plugs and install plugs.

for rethe en-

Inspect the spool and spool bore scoring or other defects that would sult in excessive sp:>ol leakage. If Bpool or its bore is defective, the tire section must be replaced.

Inspect the machined surfaces of the valve sections for burrs and nicks. Use a fiat India stone and remove any nicks or burrs, Figure 11. Move the stone in a circular motion and keep it flat at all times. Do not stone a section that has not been completely disassembled. Thorougbly wash the valve section in cleaning sol vent to remove all traces of grit.

Assembling Control Valve Figure 11 - Stoning a Valve Section 5.

CheCk springs for distortion and signs of cracking. Replace if either condition Is evident. If spring testing equipment is available, check all springs against specifications on page 4107-2.

Place a small amount of clean grease in the O-ring recesses (4) in eacb valve section. Then place new a-rings in each recess.

Install the four tie bolts in the inlet section. Then place inlet section on bench with tie bolts up.

Install the working sections in the sequence established during disassembly. Make sure shims used between the valve sections are in place before the next section Is installed.

Assembty of Working Sections 1.

Refer to Figure 13 or 14. Install new O-rings on load check: valve plugs and lubricate with clean hydraulic oil. Hold the valve section upright and install a load check. valve and spring. Place check

Continued on page 4107-22

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•

4.107-19

•

'"I

1. 2. 3.

OOTl.rr SECTlOl'l SENSING PISTON O-RlfUi

REGENERATION SPOOl

S. SPRING 6.

PLUG

1. 8.

IrtLrT SECTION POPPET

POPP£T SEAT (REFER TO DISASSE!eLY

AND ASSEMBLY Of INLET SECTION)

10. SHIM

15!591

Figure 12 - Inlet and Outlet Sections

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•

4107-20

'B" 0,

0, o

\&J1O 0'

;!112

~. \. 2.

J. 4. 5.

SPRING

u.~

SNAP RING SPRING GUIDE SPRING

RETAINER

O·RING SPOOL 8. WIPER

II.

5. 7.

SECONllAIH RELlEF 10. OIECK VALVE PLUG

CHEC~

VALVE SPRING

12. CHECK VALVE 13. SHlI1

~AnE

14. PLUG (USEO ON

EXTENSI~

SEer ION ONL V)

'11m

Figure 13 - Boom, Dipper, Bucket and Extension Valve Sections

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•

4107-21

• •

l.-'

1111

s©>

1D@ 0.

3<gl

·1

36 ,e>

, It?'

SPRING CAP SNAP RING

SPWIG GUIDE SPRING RETII.INER

"',.'1 " ...i~.,.,

••s. ••

()..ltl~

,. •• ". H.

- .0

12.

...

AHTICAVlT"T1C1H YALVE

CKEtK VACYE"Sl'!! lfIG

AHTlCAVlTATIOH VAL'IE PQI>PET

CHECK Y""V£

16.

,MOt

WIPER SECOO!lARY mlEf VALVE CHECK. VALVE R UG

13.

FIgure 14 - Swing Section

"-"'

SI'RI~

751~"

•

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• 4.

Inatall the outlet sec t ion and s c rew nuts on Ue bolts finger tight. Lay control valve on bench and torque the nuts evenly to 20-30 foot-pc.unds (27-41 N m) in increments of 10 foo t-pounds (13 N m). If the nuts are tightened unevenlyor over tightened, bind log spools may result.

0' @l

o·

If a secondary rel ief valve adjusting s crew has been d1Bturbed or a new reHef valve has been iDstalled, check and

adjust the pressure setting as instructed 10 section 4002.

Secondary Rellef Valve

Disassembly

4i;j>

~Il

Refer to Figure 15. Place the c artrIdge in s viae and remove the adjusting screw lock RUt. Nut is torqued to 50-80 inchpounds (6-9 N m).

~Il

Remove snap ring. Note number of ex-

o· O·

posed threa.cls on adjusting screw.

The remaining parts now c an be easUy removed. The piston and poppet may be held by the fit of the O-ring.

Remove and discard O-rloga,

Inspection 1.

Inspect the spring for signs of dlstortiOD and c racking. Check spring OD a spring tester--if It doe s oot meet spec ificatioll8 OD page 4107 - 3, replace with a Dew spring. Inspect poppet and its seatlog surface. If seating surface is damaged, the enUre relief valve mus t be replaced.

Assembly 1.

Assemble parts in the order Shown in Figure 15. Assemble adjusting screw in approximate position noted during removal. Install cartridge in valve section and torque to 65-85 foot- pounds (88-115N m).

2. 3.

USED IN SVI!IG S£CTICW A AIID B PORTS, AHD BOOH SECTION A PORT. USED I" IUO:£T Nfl) DIPPt:1I SECTION .I. AH() a POIITS • .I..'iD 800H SECT IDII B POIIT LOCk NUT. TOR~E TO 50-SO IIIOI-POUII!lS (5.6·'''_).

•

~T1ftG ~CR[W

S. 6. 1.

SlW' RI~ IIfTAI"ER PISTON

ID. SPlt I'"

O-R ING

STIlI' PI"

11. I'OfIPET 12. CARTlItOGE

Figure 15 - Secondary Relief Valves

Checking Bnd Adjusting Pressure Setting Relief valves can be checked with the control val ve on or of! the machine. Refer to Section 4002. NO~t A nominal setting Is s~d OD the cartridge. Th1& setting is not to be used for those relief valves tested witb. a hand PUlqI. Spec1ficatlona and instructions are given in Section 4002.

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â&#x20AC;˘

U07-23

U fitting was removed (rom bottom port in the boom section or a new section was installed, make sure restrlctor 1a installed in the bottom port, large dia-

In.lallation NOTE: The control valve weighs approximately 95 pounds (48 kg). Use care when handling the valve to prevent personal inJury or damage to the valve.

Position valve against mounting plate and secure In place with bolts, washers and nuts. Be sure flat washers are installed between the valve and mounting plate.

to valve spools.

Connect control linkage

Connect 008es and tubes to control valve.

meter first. Torque fittings to specifications in Section

10~.

Start engine and run at low idle. Operate all cylinders through several complete cycles to bleed air fromthe control valve and hydraulic circuits. Do not bottom the cylinders in either direction during the first two cycles. Stop engine and check for oil leaks. Check reservoir oU level and add oU as required.

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Section 4109 STABILIZER CONTROL VALVE

J I Case

A Tenneco Company

C. E. Dlv. 9- 66015

February 1976

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•

4109-2

SPECIFICATIONS Ports and spools Spool travel, neutral to presaure . . . . • . . . . . . . . . . . • . . . 5/ 16" (7.9 mm) in and out Spool moved in . . . • • • • . . • • • • . • • • • . • • • • . . . • Upper work port pressurized Spool moved out. _ . . . . . . . . . . . _ • . . • . . . . . . . . _ Lower work port pressurized Port thread Inlet and power beyond ports . . . . . . _ . . . . . . .. . . . . . . . . • . . . . • . 1-1/ 16" - 12 Work ports and ouUet port . . . . . . . . . . . . . . . . • . . • . . . . . . . . _ •.• 7/ 8"_14 Springs Free Length Compressed Length Spool centering 15/16" .687" at 26.1 to 31.9 Ibs. (17.4 mm at 11.8 to 14.4 kg) (23.8 mm) Check valve 1.083" .750" at .4 to .6 Ibs. (19 mm at 0.18 to 0.27 kg) (27.5 mm) Spool cap torque . . . . . . . . . . . . . . . . . • . . . . . . • • . . .. 3a-40 foot-pounds (47-54 N m) Plug . . . . . . • . • . . . . . . . . • . . • . . • . . . . . . . • • • . . . . 35-40 foot-pounds (47-54 N m)

Special Tool Make two plates to dimensions in Figure 1 to compress the spool centering springs whenever Ii spring is removed or installed.

II-

1-~-2---j1_

•

'> f-6

')l., 't' ·1-

IW:£ F'R!JI COLD ROlLf' 5fm. rwu: T'IID PIE C(.S 12. 3.

5. 6.

III" U . 2 ..) 2- 1/Z" 163.5 - } I· l IZ' 38.1 ""J 1· 1/." 0 1. 8 _J 1/4" 0 9. 1 ... ) l i/1S- 0 1 .S no}

1. 8.

I l

5/16" Dl~. (7 .9 ..) IJIl6" (20. 6 _) T(lI> PLA T£ 11116- (I7.5"'J lDn Ctl PlAn: 111SlI

Oll flow through the valve with spoolS in neutral and with one spool actuated is shown in Figures 2 and 3. Note thst when Ii spool is actuated, Figure 3, flow of 011 through the valve to the baokhoe is blocked by the spool. However. because the spools in the stabilizer valve are a random fit. some oil will flow past one or both spools in some valves. Because of valve design. both stabilizers can be moved at the same time. The check valves are located at the bottom work ports. When the stabilizers are lowered and the spools are In Neutral (usual operating condition) the poppets are held on their seats. locking oil in the closed end of the cylinders. This prevents the backhoe from setWng.

Figure 1 - Spring Compressor Plate

Operation This open center control valve contaJns spools and two check valveswlthplunger. Each sp:>al and check valve controls a stabilizer cylinder. ty,()

To allow the flow of retum oll through the check valve when the cylinder I.s being retracted (stAbilizer raised), the poppet is heid off the seat by the plunger wbicb is moved by pressurized aU at the upper work port. See Figure 3.

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41()9-4

Removal 1.

Remove the spools:

Cab equipped models: Remove thebackboe from the tractor. All other models:

Unscrew the spool cap. Cap is torqued to 35-40 foot-pounds (41-

Removal of the backooe from the tractor

M N m).

will provide additional working space. but the control valve can be removed (with some d1Hlcu1ty) wIth the backhoe

Grasp the spool at the cap end and pull from bore.

attached.

Lower the stabilizers to the Door or raiBe the stabilizers and Ue the stabilizers together with beavy wire or cham. or blocirup mounting frame if backooe has been removed.

JI the backOOe is not removed. remove the operator's seat.

With the engine sbut off, move the subDuer control levers in both directions to equalae circuit pressure. Tben dis-

Remove busbing and O-ring from cap end of spool bore (if they did not come out with the spool).

Remove O- ring from oPPOsite end of spool bore.

Remove the spool centering spring:

Place spool in a SOFT JAWED vise.

Compress the spring USing toM:l shop made retaJner plates as shown in Figure 4.

Remove snap ring. Release spring, then remove washers, spacer. and centering spring.

connect linkage from the spools. 5.

Disconnect bases and tubes from the control valve and close openings with clean caplugs. Then remove the nuts and

washers from the mounting bolts. 6.

Remove control valve and spacer from mounting plate.

Diaa.sembly NO"'I

Tag or otherwise identify parts

as they are removed to assure proper assembly. 1.

Remove the check valves:

Remove the check valve plug. The plug is staked and may be difficult to remove, Squirting 011 on the threads will be helpful.

1!1~1l

1. 2. 3.

With the plug removed, the remaining parts in tbe check: valve &6sembly sbould be easUyremoved. Reach into the plunger bore with a piece of wire and remove the seat.

SPOO'.. CCMPRÂŁSSOR PlATE BOLT AND IfUT

4. 5. 6.

SAAP RING SPRIHG WASHER

Figure 4 - Compressing Centering Spring

Inspection c.

remove a-ring from plunger bores, use a long sharp pointed instrument. Refer to FIgure 5 for a-ring location. To

Discard O-rings. Clean all otberparts in cleaning solvent. Dry with moisture free compressed air,

(

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4109-6 2.

Inspect the spools and spool bores for scoring and other defects that would result in excessIve spool leakage. If inspection Indicates replacement of a spool or the val ve body, the complete valve must be replaced.

Install spool cap and torque to 35-40 foot-pounds (47-54 N m).

Assemble and install the pa..rts in the check valve assembly as follows: a.

Inspect the check val ve poppets and seats for wear and replace it necessary.

Inspect the cbeck valve plug threads and plug threads In the valve body. Clean up threads If damage Is present. Be sure all traces of metal particles are removed from the valve body.

Install a new a-ring on the plunger seat and install the seat carefully into the bore.

b. c.

LubrIcate the remaining parts and install.

If a centering spring was removed. assemble the spool as follows:

Screw the plug into the bore until It seats. Torque the plug 35 to 40 fooH:ounds (47-54 N m).

Using a sharp punch, stake the plug in four places to lock into place. Check the plug by revening the torque. U the plug turns out before

30 foot-pounda (41 N m) Is reached. restake the bottom of the plug.

AsSemble washers. spacer. and ceoterine spring on end of spool.

Compress the spring as shown in Figure"

Installation 1.

Attach valve to mountingplateawlthnuta. oolts. and washers. Use spacer at upper mounting bolt.

Connect hoses and tubes to the control valve. Torque fittings to specifications

Install map ring in groove on spool.

Install lubricated a-ring in groove at spool eye end of spool bores.

Install buShIng on spring end of spool. large O. D. toward spring. Then install new O-ring on spool.

Lubricate spool with hydraulic oU and slide the spool Into its bore. Install sJX>OI In its origfDal bore--do not intermix.

Lubricate and install the plunger carefully into the bore.

Inspect the plunger and plunger bore !or scoring, burrs or otherdefeots thatoould interfere with movement of the plunger.

Inspect springs for distortion and signs of cracking. Check spring tension: see page 4.109-2 for speoifioations.

Assembly I.

Lubricate the plunger bore and install a new a-ring.

Lubricate parts attached to spool with Lubrlplate.

in Section 1051.

Connect linkage to valve spools.

Jnstall backhoe on tractor. if removed.

start the engine and move the stabilizers through several cycles to remove any trapped all' and to check for leaks.

(

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Section 4121 BOOM LOCK SYSTEM

J I Case

A feon.co Comoan,

C. E. Dlv. 9-66015

_ _ .. u .....

February 1978

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•

.u21-2

OPERATION General The optional boom lock system Improves

cannot settle due-to leakage past the boom spool (411 spools leak slightly due to valve clearances).

the craning or load handling capacity of the

backhoe. The system consists of the control valve with relief valve and the necessary roses and blbes to connect it into the boom circuit. When the control valve bandle Is in the Closed position, the 2750 psi (18 960 kPa) relief val,", at the bottom port of the boom section Is locked out of the boom cylinder circuit.

The boom cannot be lowered hydraulically with the control valve In the Look pOSition. The boom can be raised hydraulioally with the oontrol valve in the Lock position if pressure In the boom circuit Is below setting of main relief valve. Refer to Figure 2. The center of the control valve shaft is ecCeDtric. WheD. the lever is moved to the Closed position. th1a eccentricity allows the poppet spring to Beat the poppet against its seat in the valve body. When the load pulls down on the boom, 011 between the boom cyl inders and the control valve is blocked by the seated poppet. Tbe heavier the load, the more firmly the poppet Ls seated.

If pressure in the locked circu1t reaches 3400 psi (23 442 kPa), the relief valve w1ll open and vent oll to the reservoir.

STATI C OIL OIL l OCICEO lit 800M CYl iNDERS OIL DISPlACED FRCfI 800II CYLl tfD£RS

, I. Z. 1.

COt!TROL VALVE

VALVE OPEN VALVE CLCS£G

6. eOOK CYLINDE R

• • TG RtSlIlVOIR_

2750 PS I (Ie 960 kP,) RELIEF VAL VE ~lIn

Figure 1 - Boom Lockout Hydraulic l.J !agram The relief valve in the boom lock control valve Is eat to relieve at 3400 psi (23 442 kPa). Tbia higber pressure settmg allows movement of heavier loads . In addition, the boom

•.

IWIDl£ POPPET

2. 5.

SHAFT SPRIIE

RELIEf VALVE

"IS"

Figure 2

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•

4109-5

U !I 1 1

•

03.

I' "I ijt

13@

if,:

@' 00,

•

,,~

\. SPOOL CAP

7. O-l!UIG

2. SNAP lUNG

8. BODY

13 • .sEAT J4. PLUNGER

9. SPOOL

15. STAKE PlUG IN fOUR

3. WASHER

PlACES

4. CENTERING SPRiHG

10. PLUG

5. SPACER

11. I'OI'PET SPRIHG

12. POPPET

6. BUSHING

151570

Figure 5 - Control Valve

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4121 - 3

CONTROL VALVE Removal

Completely retract the dipper and lower boom until bucket is resting on the fioor.

With the engine shut off. move the boom control 1ever in both directions to equalize circuit pressure.

Disconnect tubes and hose from valve fittings and remove valve. Close all openings with cap or p lug as required.

Disassembly

Remove plug from bottom of valve, The s pring. spring sent and poppet should be removed with the plug. If no t . the parts are loose and will fallout.

Through the plug opening, grasp end of plunger with needle nose pliers and pull plunger from vah'e. The plunger is held in the valve by the fit of the O- ring.

Remove lower front panel from the control tower. Remove the control valve mounting bolts and remove top panel from control tower.

I~l~'~

Figure 3 -

wckout Control Valve In s t allation

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•

Remove relief valve. The relief valve is nonadjustable and nonrepairable; DO NOT attempt to disassemble the relief valve.

Remove screw from spring clip, and snap ring from end of shaft. Tben pull shaft from body.

Remove all a-rings and backup rings and discard.

Inspection 1.

Clean all parts In cleaning solvent and dry with moisture free compressed air or allow to air dry. Inspect the seating surface on the poppet and its mating surface In the body for damage or wear that would result In leakage. The poppet can be replaced separately. If seat in body is defective, the oomplete valve must be replaced. Inspect spring for sigJls of cracking and distortion. Replace spring U either oondiUon is present. If spring testing equipment is available. check spring aga.inst the following specUication: springsbould oompress to 1" (25 mm) at 2.2 pouncls

Lubricate shaft and shaft bore with Lubrlplate or other 8ultallle lubricant. Secure shaft in place with snap ring.

Install new a-ring and backup ring on plunger. Grasp end of plunger with needle nose plIers and start plunger into bore in the body. Then push plunger into contact with the shaft.

Install new O-ring on rlug.

Place sprlng seat and spring in poppet. Then sUde plug over poppel Install this assembly In body.

mstall new O-ring and backup ring in groove in relief valve bore. Install new O-ring on relief valve and install valve in body.

Install spring cUp. Tighten screw just enough so spring cUp will hold shaft in position selected.

•

Installation 1.

Place valve in tubes and tighten tube connections. Then connect bose to valve,

Position top panel on control valve and control tower and install valve mounting bolts, washers and nuts.

(0.99 kg).

Inspect the remaining parts for excessive wear and replace as required.

A •• embly 1.

If the shaft or pin must be replaced. press pin in until it extends .187" (4. 7 mm) beyond end of shaft.

Refer to Figure 4 and install handle on ,haft.

Starl engine and run at low idle. Operate the boom cylinders through several cycles without bottoming the cylinders to bleed air from the circuit. Stop engine and check: for leaks. Check reservoir oU level and add as required.

Jnstalliower front panel on control tower.

(

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4121-5

( 12

•

••••

••

t '

~ O~RING

SIW' RING

to . RHIEf VALVE

SPRING SPRJIIG SEAT

12.

SCREW

,", ~ E

D . CAP sew/

POPPET

PLUNGER 8.ACKIIP RING

RUBBER BACKUP RING

". 15. 16 .

SPRING CliP ". ". orr ". ".

LOCK WAStiER

m ,,,T

'!.

22.

"."

SPACER

'00'

7SI~16

Figure 4 - Lockout Valve

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Section 5002 HYDRAULIC DIAGRAM, TROUBLE SHOOTING AND PRESSURE CHECK

J I Case " Te nn. co Sompa nl

E. Div. 9- 66015

February 1976

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5002-2

Rated pump output ..

. . .. .

Reservoir capacity .•.. , System capacity •••.. ,.. Type of all , . . . . . . Relief valve pressure settlDg

SPECIFICATIONS .. 6.7 U.S. gpm at 1800 psl at full throttle (251/mln at 12410 kPa at full throttle) • , . , .•.... , • . . . . . . . . 1 U.S. quart (0.9 liter)

, ....•.•.•. · . . . . . . . 3 U.S. quarts (2.8 litera) . ..•••.• .. • • • . • • . . . . . . . . . • .. CiUle Ten fluId .•..••.•• •.• • •.• , •• , 2000 .. 100 pel at full throttle nJ 789 z 689 kPa at tull throttlAI

Plrl~

FU)II

_ Olt Hcr..' f01I. UFT l U~N _ nIL FUtJ Ff);I R[GIIT ~U!!'1 __ OIL RtTU~~

~':'I-.----- -- ------

P:.1;t::t------------_. !. S1[(AI NG CYLl!i)t R

2. SHE RalI'; PlR 3. ST[UHlG CO'ITA()L

~ALvr

' . ['IlH POA7

S. OUltCl Ml!T 6. RIGHT TIlR'1 rO;iT 7. l.EFT 11~1 P{)R!

1Sun

FIgure I - SteerlDg Hydraulic Diagram

5002 - 3

TROUBLE SHOOTING CHART PROBLEM

POSSIBLE CAUSE

Steering wheel turns freely, no response

low reservoir oil level.

Slow or hard steering

Fill to proper level with Case TCH Fluid.

Recirculation valve in steering control valve not seating.

Remove plug and steel ball and check for damage and foreign materioJ that would prevent ball from selting.

Worn or damaged parts in $teering control valve.

Remove valve, disassemble and Inspect all parts. Refer to Section 5007.

Leaking piston O-r ing in steering cylinder.

Check each cylinder for leakage. Turn wheels all the way to the right and disconnect rose at rod end of left cylinder. Start engine, mid steering wheel for full right turn and have someone observe Icllkage from left cylinder. Turn wheels all the way to the left and disconnect !:Dse at rod end of right cylinder. Start engine, tÂťld steering wheel for full left turn and bave someone observe leakage from right cylinder. Remove cylinder(s) and repair as required.

Low reservoir oU leVel.

FUl to proper level with Case TCH Fluid.

Steering pump failure.

Check relief valve pressure setting as instructed in this section. Low pressure indicates a bad relief valve or worn pump. Disassemble pump and repair as required.

Improper connections In cylinder circuits.

Check connections al{8..inst diagram.

Worn or damaged parts In steering control valve.

Remove valve. disassemble and inspect aU parts. Refer to Section 5007.

Steering wheel turns hard. no response

.---:=;;- REMEDY

Low reservoir oil level.

FUI reservoir to proper level with Cue TCH F1uid.

Worn or damaged parts in steering control valve.

Remove valve. disassemble and inspect all parts. Refer to Section 5007.

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50024 PROBLEM

POSSffiLE CAUSE

REMEDY

Slow or hard steering (OOot'd)

Low system pressure.

Check pressure setting of relief valve. If setting is not as specified. remove steering pump and replace relief valve. Refer to Section 5005

King pins blndJng.

Lubricate king plns accordlng to maintenance schedule.

Low tire pressure.

Inflate to specUted pressure.

Air In steering c1rcuiL

Bleed air from circuit.

Dirt prevents proper action of spool In steering valve.

Remove valve. disassemble and clean and repair as required. Refer to Section 5007

Touchy or err atic steering response

RELIEF VALVE PRESSURE CHECK The following items are needed to per6;)rm the pressure check: (1) a 0-3000 psi (0-20 68~ kPa, pressure gauge, (2) one swivel tee, part number 218-845 and (3) one tube cap. part number 218-755 drUled and tapped with 1/8 NPT threads. 1.

Disoonnect outlet (top) rolle from the steeclng pump.

Install cap on tee and iDstall tee betwem rose and pump mUng.

Connect pressure gauge to cap on tee.

start engine and run at full throttle. Turn wheels all the way to the right or left and observe pressure gauge.

If pressure was not as specified on page 5002-2 the relief valve muat be replaced. The valve is nonadjustable and nonrepa.irable. The relief valve is inside the steering pump; refer to Sec-

tion 5005.

â&#x20AC;˘

)

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Section

5005 STEERING PUMP

J I Case A Tenn llco

C 0n10d~'"

C. E. Div. 9- 66015

.. _

.. u ...... ,

February 1976

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5005-2

2 ,

9. r~~r~J\P SCR£II iO. LOCK WASHO I"Z .· ~EAR cnV£R n . STUll I~" G/.5K£T CAP SCR£II a .. SHORr~EDIU€ COVER 16 IN!

17. R~E~J:~~~

24 . BODY 25. S~

Ig. ~JV€ SHAfT 19. 0II.1V€N G[p,R

20. IIOOORUH

~EY

21. DRIVE SHMT

2Z. ~~.

~R()N

B[p,RI.~G GE~R f"RD~T OR 1 ~E~

26. ;~T WASHER 21. NUT 26. ~ PIN 29 .

COTTE~6"

lO . 4-15/

{l25.4 rnnl

1~lsn

BEARING

Figure 1 - St eering Pump

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"'5-3

•

STEERING PUMP AMembly

Removal 1.

Disconnect hoses at pump and close all open.lngs with clean oaplugs.

The pump lPOunUn, oup eonwa are installed from the front throu&h the t1m.1ng gear oover. Unsorew the three

U abaft seal was removed, clean seal bore in body and apply • light coat of No. 3 Permatex or equivalent to seal bore. Then press new Beal into bore.

IDstall new O-riDgs on the dri\"8D gear and drive shaft front bearfngs.

The front bearings are a close fit in the body. but when properly lined up they wW sUde fnto place. lnstall the bearin811 at tile same time with the .nats together and the tapered surfaces up (toward gears). Do not force the bearings lnto place. lAlbricating the bearings 4nd bearing bore wUl aid In lnstallaUon. Be sure bearing with the long sleeve 18 installed in the drive shaft bore,

4..

Lubrioate both gear. and install them in the body. Use care not to damage the abaft seal.

Install the rear bearings in the same manner U the trout be&rlngswttbtbetapered bearhtg surfaces towards the gears.

retAining !lut. aprfng.

Place new O-ring in groove in the intermediate cover, Use grease to bold O-ring in place if necessary.

Remove the six rear cover retaining cap screws lind the cap screw next to the relief valve.

Pla.oe new O-ring In gJ'oove kl I!I1d of relief valve, Tben install relief valve in intermediate ClOver eo it extends

cap 80r&o\.. and remove pump from eoglne,

Di.....mbly 1.

Remove!W cap and drain reservoir. T.beta remove all acoumulated dirt from pump and reservoir.

Make

H.1l

aUgllmeut ma..rk OD tho pump

and reservoir. Thla mWlt be done to assure tbe proper aU level after the pump is assembled,

Remove cotter pin from drive abaft.. Tbeo remove nut, wasber, gear and Woodruff key from shaft.

Remove reservoir retaJntng Dut, copper washer and reservoir.

Remove

ruter

washer and filter. 6,

Remove the rear oover and intermediate

through cover 1/16" (11 mm).

cover. Remove guket and O-riDg from

covers. 8. 9,

secure the body

Loosen relIef valve lock nut and reDXlve

in a viaB and place Intennediate oover on body. Then place a new gasket and the rear cover on the

reUef vaha from intermediate cover.

intermodiate cover.

Tap gear end of drive shalt with a 80ft blmmer to remove the shaft and rear bearing trom the body.

Install the six long cap screws In bolea in rear cover and the sbort cap screw in the iIltermedl.ato

COVCl',

Torque oap

screws ev-.Iy to 9-11 foot-pounds (1210, Remove driven gear rear bearJng and gear fl'OJD body. U. Remove drivElD gear and drive shaft front bearlogs from the body.

12. Remove shaft Ileal from body only if it 18 to be replaced.

15 N tn).

10. Torque relief valve to 10-12 foot-pcnmda (13-15 N m), Then torque lock nut to 18-20 foot·pounds (24-27 N m). 11. Install new ffiter and ascure iD place with

washer, ,prIng and nut. Screw nut onto

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500..... shld to obtain the dimension shovro. in Figure 1. The nut must be properly instBlled to prevent damage to the re-

install new cotter pin.

Installation

servoir. 1.

Install new gasket on pump body and install pump on engine. Install cap screws and tighten.

nut to 20-25 foot-pounds (27-34 N mJ .

Connect hoses to pump fittings.

13. Place Woodruff key in slot in drlvesbaft.

Start engine and turn the steering wheel through several oomplete turns to bleed air from the steering circuits.

12. Install reservoir and align mark made during disassembly. Secure reservoir 1n place with copper washer and nut. Torque

Install gear and secure in place with wasber

and nut. After tightenJng nut.

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Section 5007 STEERING CONTROL VALVE

J I Case

A Tenneco Company

C, E. Div. 9-66015 February 1916

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5007-2

TABLE OF CONTENTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 5007-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5007-3

Spec1:ficatlons

Operation

OeDeral . . . . . . . . . . . . . . . • . . . . . • • . . . • . . . . . . . . . . . . . . . • . . . . • . 5007-3 Oll Flow, Right and Left Tum, Engine Run.ning ....•••••••••••.••..... 5007-4 Oll Flow. Right and Left TUrn. Engine Not Running • . . . . . . • . . . • . . . . • • • • 5007-6 OU Flow. Control Valve in Neutral . . . . • . . . . . . . . . . . . . . . . . . . . • . . . . • 5007-8

Servicing the Control Valve ReIDOval

. . . . . .. . . . .

. . . . . . . . . . . . . . . . . . . .. . . . . . . 5007-9

•.......•••••••••••••••••••••••••.•••••••••••••• 5007-9

General Information ....•••••.••••••.•..•.••.•.••••.••.•.•••• 5007-9

Inspection Assembly

InstaUaUoo

steering Column

... .... . .. .. . . . .. .. . . . ..

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5007-9 · . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5007-11 · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5007-12 · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5007-16

Dlaaasembly

... .

. ..

.••••••.•.•.•.•••••••.••••.••••••••••••••••••

S007-17

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5007-3

SPECIFICATIONS Wear Specifications Commutator and commuto.tor ring WckneQ8 diffel"er1 ce . . . . _ . ..

Rotor and stator thickness dilieren~e . . . . . Rotor and stator clearance . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Torques Cover cap screws atd plate cap screws Steering wheel Dut

.. . .

........ . . . . . . . . . . . . . . . . . .. . . . . .. .... . .... .. . ..

,0015" (0.038 mm) max. ,002" (0.051 mm) max. .006" (0.152 mm) max.

18-22 foot-pounds (24-30 N m) 15-19 foot - pounds (20 - 26 N m) 32- 37 foot-pounds (43- 50 N m)

OPERATION General

Duo to design. it 111 imprll ctlcal to present an lllustratloo that v,'Ould cleuly show

Refer to Figure 5. The steering control valve consIsts of three major assemblies;

the flow of oil through the metering section.

the ooDtrol sectioo. control valve section

'Ibe function of the commutator . co mmutator ring and manllold is to direct the flow of aU between the gerotor and control valve sect ion. The commutator turns in unison with the steering wbee1 and rotor.

slid the metering section.

Control VaNe Section The oontrol

valve sectioo contains ' a

mechanically actuated linear, opec! center type spool. The spool I.i centered in the housing by the torsIon bar.

Tbe functions of the control valve section are: 1.

Diroot aU frQm the 8teerlng pump to

the metering section (steering wheel turning) or to the ~tlet port (steering wheel at rest). 2,

Receive oil from the metering section and direct it to the steering cyl inder s.

Direct return oil from the cylinders to the outlet

Metering Section The metering section oonsists of the gerotor (rotor and stator), commutator. commutator ring and manliold.

Controlling aU flow to the cylinders is

the primary tlmction of the gerowr. The gerotar consists of the stator (gear ring) and rotor (gear). The rotor has six lobes and the stator seven lobes, The rotor ball one less lobe to form the pockets required to perm1t oil flow through the complete valve assembly. WbelI the steering wheel is being turned, the rotor and co mmutator also rum. admitting oU to three expanding pockets , and dIscharging au from three contracting (shrinking) pockets. The seventh pock.et is inactive ~ It changes fro m discharging oil to admitting oil. U the .angine stops, and the steerlnlt wheel Is turned, the gerotor then functions as a pump to permit continued steering of the machine. However, with a dead engine,

steering effort Is greatly inoroused. In cue

of a power fuilure the machine should be brought to a stop as quickly as possible,

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5007-4

Oil Flow, Right and Left Turn, Engine Running 1.

AB the steering wheel starts turning, several actions occur &1most simultaneously: B..

The spool starts to move into the valve (right tum) or out of the valve neft tum) aUowing 011 from the steering pump to charge the metering secHon.

metering section and control valve section. At the same time, the rotor and commutator turn, directing 011 to the control v&1\'e section and steering cylinders. 2.

IN'ben the steering cylinders reacb the end of their trav81, â&#x20AC;˘ hydraulic stop is created because the metering sectioo can no longer dlScharge 011 and the steering wheel can no longer be turned. U the steering wbeel is beld against this hydrauliC stop, the relief valve in the steering pump opens and diverts oU to the reservoir.

When tbe operator stops turning the steerJng wheel. the spring action of the torsion har returns the spool to neutral, bloCking the passages to the cylinders and the front wheels bold their last position, straight ahead or turned right or left.

The rotor and commutator, which are connected to the Input shaft through the drive Unk and torsion bar, resist turning because of cyl-

inder preseure required toovercome the steering forces.

Continued rotation of the steering wbeel (even sll.gbt movement) moves the spool farther into or out of the v&1ve, opening ports to the steering cylinders, and passages between the

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5007-5

FLQ\oJ RETURN OIL FROM ~YLINDERS TO RESfRVOIR MET ERED OIL TO CYL HIDERS

- p ut~p

1. SPOOL 2. ROTOR 3. CO/'VoIUTATC1R

4. INPUT SHAFT 5. DRrVE LINK 6. TORSION BAR

7. ACTUATOR BALL CONFI NED I GROOVE BY SPOOL. CLOCKWISE ROTATIOfi OF IItPUT SHAFT t-IOVES BALL TO BOTTot~ or GROOVE AND SPOOL INTO VALV E.

Figure 1 - Oil Flow, R ight Turn, Engine Rwming

PUMP FLOW METfRED OIL TO CYLI NDERS RETURN OIL FROtÂ·, CYLINDERS TO RESERVOI R

GROOVE

~~~. -~. 4 -

1. SPOOL 2 . ROTOR 3. CQf'lHUTATOR

4. I NPUT SHAFT 5. DRIVE LINK 6. TORSION BA.R

- - ..... r--'"

7. ACTUATOR BALL CONFINED IN GROOVE BY SPOOL. COUNTERCLOCKWISE ROTATI ON OF INPUT SHAFT t'lOVES BALL TO TOP OF GROOVE AND SPOOL OUT OF VAL VE .

Figure 2 - Oil Flow, Left Turn . Engine Running

151586

5007-6

Oil Flow. Right and Left Turn. Engine Not Running Steering the machine with a dead engine 18 possible because the gerotor functions as a pump when the steering wheel is turned (much greater manual effort 18 required). EssentWly, the gerotor recirculates the all oonta.lned J.n the control valve, steering cylinders and lines to and from the cylinders. 1.

Aa the steering wbeel 1.8 turned, the spool moves into the valve (right turn)

or out of tbe valve (left turD) opening paa,sages between tbe metering section and oylinders.

When the spring action of tbe torsion bar is overcome. the gerotor thenpumps all to the cylinders.

As the pistons in the cylinders d.L8p1.ace all, tbis all Ls directed to the control valve inlet via the recl.rculation valve and the connecting passage between the inlet and outiet porta.

â&#x20AC;˘ I '-""

No-r.: When tbe engine 18 running the recirculation valve blocks oil flow to tbe ouUet p:>rl.

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5007-7

RETURN OIL FROM CVLlIIDERS OIL TO CYLIHOF.RS

~TERED

1. SPOOL 2. TORSION 8AR 3. DRIVE LINK

4. GEROTOR 5. I NPUT SHAFT 6. RECRICUUITING VALVE

7. ACTUATOf\ BALL CONFI /i ED III M OOVE BY SP()OL. CLOCK1JJSE ROTATI ON OF IltfllJT SHAFT f10VES BALL TO BOTTOH OF GROOVE AND SPOOL INTO VALVE.

751SG7

Figure 3 - Oil Flow. Right Turn, Engine Not Running

~ ETURN

OIL

mo....

CYLI NDERS

4. GEROTOR

1. SPOOL 2. TORSIO'. BAR 3. DRIVE LINK

5. THPUT SHAFT

6. RECIRCULATING VALVE

7. ACTUATOR BALL CONFrNED IN GROOVE BY SPOOL. COUNTERCLOCKWISE ROTATION OF tN-PUT SHAFT MOVES aALl TO TOP or GROOVE AND SPOOL OUT or VAlVE .

Figure 4 - Oil Flow, Left Turn , Engin e Not Running

7S l58EI

5007- 8

Oil Flow, Cont rol Valve in Neutral Refe r to Figure 5. With the steering valve in n eutral , o il fr om the steering pump flows through the valve to the pump reservoir. The spool lands block oil flow to the steering

cylinders, permitting the machine to bold its direction. To change direction, the steedng wheel must be turned.

1. lNLET PORT Z. OUT LET PORT 3. LEFT TURN OUTLET, RI GHT TURN RETURN

4. RIGHT TURN OUTLET. LEFT TURN RETURN 5. METERING SECT I ON 6. CONTROL VALVE SECTION

7. CONTROL SECTION 8. CO~~UTATOR RI NG 9 . CQt" 1UTATOR 10 . HANI FOLD 11. GEROTOR (ROTOR AND STATOR )

Figure 5 - Oil Flow, Control Valve in Neutral

5007-9

SERVICING THE CONTROL VALVE Removal 1.

Remove fioor plate. Then remove accumulated dirt from control valve, fittings and surrotulding area.

Remove steering wheel,

Disconnect tubes at control valve and plug tube openings,

Loosen steering column clamp at the control valve andon frontofinatrumentpanel. Raise column to expose the shaft coupling 8J1d remove the lower retaining ring and pin. Remove the column and shaft.

Remove the four ferry head mounting cap screws and remove valve from machine, Do not allow valve to fall when removing the cap screws.

General Information 1.

Before disassembling the control valve, cap the fittings and througbly clean the exterior of the vaJ ve.

Disassemble and assemble valve on a clean work bencb and use clean tools,

Parts srould be cleaned only In a clear,

Figure 6 2.

clean petroleum base solvent and dried witb moistu.re free compressed air o r be allowed to air dry. Do not wipe parts with a cloth or steam clean, 4.

Some parts of this control valve are replaceable only as part of a set or in a complete control valve. Refer to parts catalog.

Use care in completing steps 3 through 8 to prevent damage to the ground and lapped surfaces of the components, NOTa:

To prevent possible damage to the control valve if placed directly in a vise, the following procedure smuld be used. Remove all fittings from the control valve except the fitting In the outlet port. install a tube cap (part no. 218-754) on the fitting. Reposition fitting as required so valve can be secured in a vise as illustrated In Figure 6.

Grasp end plate and retainer and lift these parts from the body. Then separate end plate and retainer. NOT.: Sepo.rate parts tha.t are stuck together with a sliding and 11ftingmotlon.

Disassembly 1.

Remove the seven end plate cap screws.

The commutator ring may come with the end plate. Remove commutator ring from end plate or manifold.

Separate manifold from the stator and rotor.

Remove the stator and rotor, and spacer and drive link as an assembly. Figure 7.

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5007- 10 stator and rotor assembly on the bench and lift stator from rotor. Tbeo remove vanes and springs from the rotor. 9.

Repos1t1on control valve in the vise with the input shaft up. Mark the cover and body with a center punch as shown in Figure 9 to assure proper assembly.

-.-. â&#x20AC;˘

Figure 7 Refer to Figure 8. Remove drive Itnk by sl1d1Dg the stator and rotor on the spacer allowing the drive link to drop through the spacer.

Figure 9 10. Remove the four cover retaining cap screws using a 5/16" 12 point socket or box end wrench. The spool is a close fit in the body but is eas11y removed U pulled straight out. Never force the spool out of the body. NOT":

11 . Grasp the input abaft and w1th a smooth upward motion remove the cover. sba1l: and spool as an assembly. Then remove O-ring from face of cover.

Figure 8 8.

Hold the spacer and stato r and rotor straight up and down and remove spacer using a sltdlng motion. The spacer should be removed in thi9 manner to prevent the rotor tram falling out ofthestator. Place

12. Wrap spool with paper. hold spool with one hand and pull cover from shaft. The spacer in the cover will be removed with the spool. 13. Remove shims from cover bore or input

sbaft and tie shims together for use during assembly.

H. Use a sc rewdriver and pry dirt seal

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5007-11 Then relD)ve SDap riD&, SlId spacer. seal and aeal riDg.

'from oover.

15. Remove snap rin8'. tbrwIt washers and thrust bearing. and sprinl from .irl.put ahaft.

18. To remo'V8 the drive rlDg. place open snd of apool OD. benoh snd rotate input thaft to extremes of travel unW drive ring falla free, Figure 12.

16. Place input llbaft on a block of soft wood

u Ulu.tra.ted in f'i&ure 10. Uae drlft: pmoh with a maximum d.iameter of.120" (3 mm) ud drive torsion rod retaining pm out of lnp.1t abaft.

Figure 10 17. Remon tonkm bar ibid apacer by mldtng opal end of 11Âť>01 down md allowing the parts to fallout &8 ahown in Elgure

11.

19. With opea. ea.d of apool down. tum inplt ahaft. oI00kwiae to dilleopee actuator ball IUld reDÂťve abaft from apool. The ball will probably drop !rem the tpool; use care Dot to 10M ball. 20. Do Dot remove ball retainer from spool UDleaa the reta.l:Der is to be r~aced. To remove the reta.iner. grasp the ball end with needle noae pilau aad work it over the end of the apool. A screwdriver may be UIIad to a.id in removal. Uae care to prevent damage to 'pool landa and remove any burrs made whJle removing t.be retainer.

21. Remove body .from vise and remove plUi and steel ball from body. Thee. pa.rta: make up the recIrculatJon check valve.

Inspection

FlsureU

Clean III part. .In olean petroleum. buill lIOiVSlt and dry with molature tree oom-

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S007-1Z

pressed air or allow the pa.rta to air dry. Use care not to damage the lapped and machined surfaces. 2.

Inspect the valve body ends and spool bore iJr wear and damage that would

result 10 leaks or improper operation. 3.

Inspect sp:>ol lands for wear, scoring, etc. Some burnis.hiDg of spoollanda may be observed and is acceptable. Aleo in-

spect splines in spool for wear. U either the spool or valve must be replaced, the complete

NOT.I

body

valve must be replaced..

Inspect Jnput shaft seal area for rust, pItting and excessive wear . Ligbtpol1sbin, in the seal areas may be observed lind 111 acceptable. Also inspect spiral ball Foove for pitting, chipping Wld surface breakdown. Ie_poet thrust bearing and wasbers for

piWD&t acoring, etc. 6.

Inspect drive Unk teeth for exceaaive wear. Also check width of slot in drive link. Uee a pair of inside calipers and micrometer . U the width of the slot varIes more than .001" (0.0254 mm) the drive Unk. must be replaced. Meuure diameter of pin in the torsion bar. If the diameter varies more thaD .001" (0.0254 mm) the torsion bar mWlt be replaced. The spacer, man Lfold. rotor, oommutator ad end plate must be free of n~, burrs and scoring on the machined sudaC8I!II. Measure the thickness of the rotor 8Jld stator. H tbe d1fference between the two parts exceeds .002" (0.051 mm) they must be replaced as an assembly.

10, Install the rotor in the stator and mea-

aure rotor to stator clearance as sbo'tlon in Figure 13. If the clearance exceeds

.006" (0.1524 mm) the rotor and stator mldlt be replaced as an usembly.

Ftgu.re 13 11 . Measure the t.hickDess oftheoommutator and commutator ring. U the differeoce exceeds . 0015" (0.OS81 mm) the parts must be replaced as an assembly.

Aaaembly 1.

mstalln8w O-ring on recirculatlngobeck valve plug. Place check ball in valve bo<ly and Install plug. Torque plug to 10-14 Wet-pounds (14-19 N m),

Install small D.D. thrust washer, thrust bearing and large C.D. thrust washer on input ,haft In this order and secure in place wIth sna.p ring.

J! ball retainer was removed from the spool, Install new retainer using care not to damage the spool.

Place actuator ball in seat in spool.

Install wave spring over thrust bearing. The spring should rest aga.Jnat the large C .D. thrust washer. Install input shaft in ap:>ol turning sbaft oounterclockw1.se to eoga.ge actuator ball with spiral groove in shaft. Perform this operation bolding the spool and sbaft in a horizontal position .

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5007-13

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I. DIRT SEAL 2. SNAP RING J. SEAL SPACER ,. SEAl RING

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6. COVER 7. CAP SW'oI 8. ~11tG 9. SHUIS 10. lAAGE 0.0. THRUST

WASHER

....,

11. THRUST BEARttIG 12.. StW..L O.D. THRUST

""13.1II\'fE SPRING 14. -SPACER 15. I~PUT SHAFT 16. PIlI 11. IAU RETAINER IS. ACTUATOR BAll 19. SPO(l. ZO. DRIVE" RING

21. SPACER 22. TORSIOH eAR 13.PlOO Z4. G-RlltG l5. CHECK IALL 26. PIM V.PlL16 28. IIOIIY

RETAINER lO. SEAL 31. SPACER

32. 33. 34. 35.

OIUYE lIKK STATOR ROTOR SPRING(S)

36. VANE (6)

37. MAHIfct.O 38. CCIMITATOR RIIfG :19. C(JM1I'ATOR 4{). WASltEJI 41. EM) PlAT[

42. CAP SCREW (7) IUSIt

Figure H

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5007-14

Using the middle of the torsion bar as a gauge. place torsion bar between small 0.0. thrust washer and spool as shown in Figure 15.

Figure 16 lowered s traight Into tbe valve body. Do not force the spool into place. Figure 15 7.

Stand spool assembly on Input shaft. Make sure torsion bar rema.ins in place.

Drop drive ring into spool and align with spool. If the drive ring does Dot engage the shaft. rotate the shaft as required so drive rIngw1l1 dropontoshait. Make sure drive rIng is seated agalns t 10put shaft and remove torsion bar.

Place spac er on torsion bar and start torsion bar into 10put shaft. Align holes in shalt 8.Ild torsion bar 8.Ild use drift punc h to m.a.intaln align ment .

10. Install retaining pIn and t ap lightly several Urnes to start pin into torsion bar.

Place spool assembly 10 pre ss and press pin into place. Use a relatively larger dIameter 1/ 2" drive socket for shaft support. Figure 16. Then use drift punch and drive pin In until about 1/32" (0. 793 mm) below the shaft O.D.

13. Coal cover O-ring with clean grease and place O-ring in groove in cover.

14. If the Input shaft or cover were not replaced. the cover can be installed using tbe original shims. If a shim Is damaged replace it with a new shim of equal thickness. a.

Place shims on top of large O. D. thrust washer and install cover.

Align mark OD cover and valve body and install cap screws finger tight.

Install a 'NOrm drive bose clamp around body pUot and cover.

Tighten clamp to center cover OD body and torque cap screws to 18-22 foot-pounds (24-30 N m). Then proceed to step 16.

15. If the input shaft or cover was replaced. the following procedure must be used to properly position the spool in the valve

body. 11. Secure valve body In vIse as Ulustrated in Figure 17. Make sure top of body l.a up (locate alignment mark made during disassembly). 12. Slide spacer all the way onto ths spool and Install spool assembly in valve body. The spool is eas ily Installed If It is

Place original shim pack on top of large 0.0. thrust washer. If a shim Is damaged replace it with one of equal thickness. Theil install cover. If original cover is being used. align marks made during disassembly. Then install cap screws fingerUght.

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Figure 18 1 Figure 17 b.

c. d.

Install worn drive hose clamp around valve body pUot and cover. Fl.gu.rel7. Tighten clamp to center oover and torque cap screws to 18-22 footpounds (24-30 N m). Reposition valve body in vise with input sbaft dovm. Install drive link in spool but do not

engage torsion bar. Graap input sbalt and pull down. PrevEllt sbaft from turning and rotate drive l1n.k to move the spool up (toward open endofbody) as far as possible• .Remove drive link, align slot in link with torsion bar pin and reinstall drive link. e,

The end of the spool sbould be flush to .0025" (0.0635 mm) below end of valve body while pulling the input shaft down, Check spool position using a straight edge and feeler gauge as illustrated in Figure 18 or use a depth micrometer. H spool position is not as specified, remove or add shims as required, A shim kit containing .002" (0,051 mm) • . 005" (0.127 rom) •. 010" (0.2M mm) and .030" (0.762 mm) shims is available.

U reshiming is required. repeat stepe: ISb through 15e. Then proceed to step 17.

16. Install drive link in spool making sure it baa engaged the torsion bar pin. 17. Inatall springs and vanes in the rotor. The springs should be .Installed 80 I!Ilds of springs contact the rotor. 18. Place spacer on work beIlcb with smooth __ surface up. Then install rotor in stator and place this assembly on the' spacer.

19. Install spacer and rotor/stator assembly on valve body. Rotate input shaft as required to align boles in stator with holes in body. 20, Note that the manifold has slots near the inside dis..r:neter on one side. Install manifold with the slotted side up (toward end plate).

with

21. Note that the commutator ring bas a groove on one side. Install commutator ring with groove up (toward end plate) and align cap screw boles.

22. Place Dew seal in retainer and place retainer on valve body. 23. Install commutator, engaging slot with drive link and wuher countersink side up.

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5007-16

24. Coat washer with clean g:reaee and place over pin in end plate. 25. Apply a few drops of oU specified OIl page 6002-3 to the commutator 8Jld manitold. 26. lnstaU end plate making gages hole In center of Rotate plate as required screw boles and install

sure pin encommutator. to align cap cap screws.

27. Alternately and progressively tighteo the cap screws to a f.1na1 torque of 1519 foot-pounds (20-26 N m) while rotatlDg tbe input shaft.

parts oatalog. Using a longer cap screw

may result in valve body damage. 2.

Tighten all tube connecUons at control valve.

Attach sbaft coupling to valve input sbaft with pin. Secure pm in place withretaJning rlng.

Slide column onto cover and tighten clamp at oontrol valve and on front of instrument panel.

Install steering wbeel with a spoke at the bottom and straight up and dov.n. Secure in place with nut but do not install cap at tb1s Urne.

start engine and run at low idle. Slowly

28. Reposition control valve in vise with

input shaft up.

29. Lubricate seal with clean oU and install seal over input sbaft. Install seal ring, and seal spacer, small diameter first on the input shaft. Then push these parts into cover bore. Secure parts in place with snap ring with rounded edp toward the seal spacer. It may benecessary to use a 7/8" deep socket or a piece of tubing with a 1-3/16" (30 mm) O.D. and 16/16" (24 mm) lD. to push parts into place. Then install dirt seal .

turn the steering wheel through several oomplete turns to bleed air from the steering circuit. 7.

H the torque readings were not as specified, shims must be added or removed to equalize the torque read1Dgs. Remove the control valve and add shims to increase left turn torque or remove shims to increase rIght turn torque.

Torque steering wheel nut to specification on page 5007 -3 and install cap.

30. I Install fittings removed during disassembly and close all openings before installlng the control valve.

Installat'on 1.

Engage valve fittings with tubes and secure valve to mounting plate. H a mounting cap screw is lost, it must be replaced by the cap screw spec1fied in the

Attach aD mcb-pound torque wrench to steering wheel nut and check: the torque required to turn the wheels in both directions with the emgine running at ball throttle. The torque readings should be equal within 2 inch-pounds (0.22 N m),

10. Install floor plate.

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5007-17

STEERING COLUMN Removal and Disassembly 1.

.Remove steering wheel.

1. STEERING WHEEL NUT 2. SHAFT

Loosen clamp at bottom of column and

on front of instrument panel. 3.

Remove lower pin retaining ring and pin and remove column.

Pull shaft out of bottom of tube.

Remove the bearing/seal assembly only if it is to be replaced.

3. BEARING/SEAl 4. TleE s. CI.AIII'

6. RÂŁTAININ& 7. PIN t. COUI'lIIlG

AS~LY

RI~G

Assembly and Installation 1.

Press new bearing/seal. assembly into top of tube,

Attach coupllng to sbaft with pin and secure pin in place with retaining ring.

Lubricate bearing bore with grease or oil and install shaft from bottom of tube.

start oolumn through instrument panel clamp

and

install

bottom clamp on

column.

Lower column assembly onto the control valve input shaft. Align boles in shaft and coupling and install pin. Secure pln in place with retaining ring. Tighten both

column clamps. 6,

H front wheels are Dot in the straight ahead position, start engine and position wheels straight ahead.

Install steering wheel with a spoke at the oottom and straight up and dovm.

Install steering wheel nut and torque to

Figure 19

32-37 foot-pounds (43-50 N m).

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Section 5010 STEERING CYLINDERS

J I Case A Tenroe<:o Co m pany

C. E. Div. 9-6601 5 February 1976

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5010-2

STEERING CYLINDER Removal 1.

Disconnect hoses from cylinder and close all openings with clean caplugs.

Remove cotter pin and nut from each ball joint. Use a tie rod removal tool to remove the cylinder or reinstall nuts with notcbes down and flush with sb.ld. and strike nut with bammer to loosen ball joint. If tie rod removal tool is used the rubber boots must be replaced.

Inspect the piston rod for straightness. Replace ifbenti do not attempt to straighten.

Before reassembling, remove any minor nicks, scratches, etc. on the rod or in !be cylinder with a medium grit emery cloth. Pollsh with a rotary motion.

Assembly 1.

If cylinder tube or cylinder ball joint was replaced, place clamp on cylinder end and screw ball Joint in to obtain the dimension shown in Figure 1.

Install O-ring in groove around gland. Install O-ring and seal in inner groove in gland bore. Install seal with lips to the inside. Then install wiper in outer groove with lip to the outside.

Disassembly 1.

Do not remove the ball joints unless the cylinder b.lbe, piston rod or ball joint Is to be replaced.

Secure cylinder in a vise using care oot to distort the tube. Removetbeouterlock ring and push gland into the cylinder about 3/4" (19 nun).

Remove the lock ring spacer and the inner lock ring.

Carefully pull the piston from the cylinder. Pull the rod straight out to prevent damage to the cyl1nder wall.

Loosen ball joint clamp on piston rod and sUde clamp onto rod. Secure clamping section of rod in a vise. Then remove piston nut.

NOTa: The seal and wiper are identical parts and must be installed as instructed in step 2.

Lubricate piston rod and gland bore with hydraulic oU. Be sure ball joint clamp is on piston rod and install gland on piston

rod.

Remove piston from rod. Then remove O-ring and backup rings from piston and O-ring from piston rod.

Remove gland from rod and remove 0 rings and wipers from gland.

Secure clamping section of piston r001n vise. Install oew O-ring on piston rod and install piston. Install piston nut and torque to 110-130 foot-pounds (149-176 N m). Then install DeW baclrup rings and O-ring in groove In piston. The O-ring must be between the backup rings.

Thoroughly lubricate cylinder wall and piston with bydraulic aU. Secure cylinder tube in vise and install piston straight into cylinder. Push the piston into the cylinder about 2" (55 nun).

SUde gland into the cylinder about 3/4" (19 mm)beyondthelockringgroove. Then install the inner lock ring. Be sure ring is seated in groove.

Pull piston rod out of cylinder to seat gland aga.Jnst the inner lock ring. Then install look ring spacer and outer lock ring. Be sure ring is seated in groove,

Inspection 1.

Discard all O-rings. baclrup rings and wtpers.

Clean all parts in cleaning solvent and dry with moIsture free compressed air.

Shine a light into the cylinder tube. If it bas deep grooves or score marks, or bas been damaged in any way, it sbouldbereplaced.

r\..J

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5010-.3

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, PROOOCTI 13.• ~(PLAC!~ CYL1HO£~ TUBE !!ALL JOIJTC~!!:!IID:II TI!IE • IIALL JOINT .........

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Figure 1

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left if the right-hand cylinder 1s being installed or to the right if the left-band cylinder Is being Installed. Remove piston rod ball joint from spindle. Check to see if piston is seated against the gland by htrning the steering wheel in the same direction. If the piston rod does not move, turn the ball Joint out of the rod until the ball joint stud is aligned with hole in spindle with Ute opposite spindle stop against the axle; then turn ball joint an additional two full turns and tighten clamp. If the piston rod moved out of the cylinder no further adjustment Is requl.red. Then torque ball Joint nuts to 100 lootpounds (135 N m). Tighten nuts to align cotter pin hole with next slot and install new cotter pin. Then proceed to step 7.

If piston rod or rod ball joint was replaced. push piston rod all the way into cylinder and turn ball joint as required to obtain the dimension shown In Figure l. Position ball joint clamps as tllustrated in Figure 1 and tighten clamps.

Installation 1.

Install cylinder in mounting boles. Install nuts finger tight.

Connect boses to cylinder(s).

If the cy:linder and rod ball joints were not disturbed, tighten nuts to 100 footpounds (135 N m). Then tighten nuts to align cotter pin hole with next slot and install new cotter pin.

If only the cylinder ball joint was disturbed, turn the wheels all the way to right or left depending on which cylinder is being installed. If the spindle stop does not contact the axle, remove cylinder ball joint from spindle and turn ball joint into cylinder untU spindle stop contacts the axle. Then torque ball joint nuts to 100 foot-pounds (135 N m). Tighten nuts to align cotter pin hole with next slot and install new cotter pin. Then proceed to step 7.

If only the piston rod ball joint was disturbed, turn the 'Nheels all the way to the

If a new cylinder is being installed, perform step 4 to be sure spindle stop contacts the axle and step 5 to be sure the

piston does not bottom against the oylinder gland.. 7.

Raise front wbeels bigh enough so the axle can be tilted against each stop. Check to see tbat bases and fittings clear all obstructions \\hen the axle is tilted against the stops and the wheels are turned all the way to the right and left. Loosen oylinder ball Joint clamp and rotate cylinder as required to obtain the necessary clearance. Then tighten ball joint clamp.

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Section 5021 FRONT AXLE

J I Case A Tenneco Com pa ny

C. E. Div. 9-66015 ' ....TlD ....

U.I.A.

February 1976

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_ 5021-2

TABLE OF CONTENTS Specifications . • • • . . . . . . . . . . . . . . . • . • . • . . . . • • . • . • • • • • • . • . • • . . . . 5021-3 Front \Vheel Bearings •...••••••••.••• •••...• ..•.•. • ••.• .•••••••• 5021-3 Spindle and King Pin

•.•.....•..•.•.•••••••••••••.•••.•.••••.••• 5021-4

Replacing King Pin and Bearings

.••.••••••••••.....••..•.••.••••... 5021-6

Front Axle • . . . • . . . . . . . . . . • • • . ., •••...• , ..•....••. , .•.••• .• •.• 5021-6 Toe In Adjusttnent •..•.••. , •••••••••••••••••••••• • ••• •••••• •.•• 5021-7

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5021-3

SPECIFICATIONS Service Toe in . . . . . . . • • . . . . . . .. .. . . . • . . . ....••. .. ..•.••...••• 0-1/8" (0-8 mm) Clean and repack wheel bearings ..•••.•.•.•••••• After every 500 boors of operation \\Ibeel bearing grease •••.••.••.••••• • • • • • • • • • • • • •. No.2 wheel bearing grease

Special Torques Wheel bearing mlt • . • . . • • • • • • . • . . .. •• 75-85 foot-pounds (101-115 N m) then back off 1/6 turn maximum Tie rod end nuts ....•..••••..•••.••...••••.• 100.-120. foot-poWlds (135-162 N m) steering cylinder ball joint nuts ....•..•.•••.. . ...•• 100 foot-pounds (135 N m) Front wheel bolts • . . • . • • • • • • • • • • • • • • • . . . . . . 115-130. foot- pounds (156-176 N m)

FRONT WHEEL BEARING Removal, Inspection and Installation 1. 2.

RaIse front wheels off the floor and block machine in place. Remove dust cap. Then remove cotter pin. nut and waSher.

bore and on each bearing cup.

12. Place inner bearing In bearing cup. Install a new hub seal with seal Up away from bearing. Use a driver that contacts the 0.0. of the seal and press or drive seal into hub until seated against sboulder in bore. F1ll cavity made by seal body

and seal lip with grease. 3.

Remove wheel from spiDdle.

4..

Remove outer bearing from hub.

Remove bub seal and inner bearing from hub. 00 not remove bearing cups unless inspection 1nd.1cates replacement.

Remove spindle seal from spindle and discard seal.

7. 8.

13. Install a new spindle seal on spindlewtth seal Up toward flange on splDdle. Use a driver that contacts the LO. of the seal only and seat seal against flange. Fill cavity made by seal body wi1h grease. 14. InsWl wheel on spindle using care natto damage the hub seal. Then install outer bearing. waSher and nut.

Clean the bearings in cleaning solvent

to remove all traces of grease.

15. Adjust bearings as Instructed under Wheel Bearing Adjustment.

Remove grease from bearing cups and spindle with a clean cloth. Also remove grease from hub bore.

16. Install dust cap.

Inspect the bearing cups for scoring. galling. etc. Also check bearing race and cage for signs of cracking.

Wheel Bearing Adjustment 1.

Rotate the wheel while torquing the nut to

75-85-foot-pounds (101-115 N m). 10.. Thoroughly pack 6.acb bearing with No. 2 wheel bearing grease.

11. Place a liberal amount of grease in hub

Wben nut torque is as specified. back the nut off 1/6 turn maximum andJ.nstallnew cotter pin.

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5021-<

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SP INDLE

Figure 1 - Front Hub Assembly

SPINDLE AND KING PIN Removal 1.

of spindle. Drive the spindle upward to prevent damage to the seal.

RaIse front wheel off the floor and block machine in place.

Remove hub dust cap, wheel bearing nut and washer. Then remove \\theel using care not to damage the hub seal.

Installation

Remove spindle, thrust bearing and thrust washer from axle.

Remove tie rod end nut. Reinstall nut, smooth side up and flush with stud. StrIke nut with hammer to loosen tie rod. Then remove nut, and tie rod from the spindle.

Place spindle In axle. Then install thrust washer between the axle and bottom of spindle and the thrust bearing on top of splndle, with bearing Shield on top.

Remove steering cylinder rod end in the same manner as the tie rod end.

Install king pin 50 notch in -pin will be aligned with lock pin hole in spindle. Install king pin from the bottom to prevent damage to the seal.

Install lock pLri- from rear of spindle with tapered surface toward the kingpin. Secure pin in place with lock waSher and

Remove nut and lock washer from king pln lock pin. Reinstall nut .auah with end of lock pin and strike nut with hammer to loosen lock pin. Remove nut and drive pin out of spindle.

nul 6.

Remove snap ring, spacer and O-ring on top and bottom of kingpin. Cbeck condition of O-rings and replace with new parts if

necessary. 7.

Use brass driver and drive king pin out

Install O-ring on top of upper bearing. Then install spacer and secure in place with snap ring. It may be necessary to use a drift punch and hammer and tap snap ring into groove.

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Tigure 2 - Spindle Installation 6.

Attach steering cyUnder rod to Gle spiDdle. Torque the nut to 100 foot-pounds (135 N m) . Then tighten nut to 8.11gn )Otter

toward :fJ.ange on spindle. Use a driver that contacts the lD. of the aeal only-and &eat seal agalnet fianp Alao,Hmovehuh seal and replace with a new eeal. Fill cavities made by seal bodle8wtth.gre~.

pin hole with next slot and Install cotter pin.

Attach tie rod end to splndle. Torque mit

1nBtal1 wheel,. outer bearing. wasber and :DIlt. Adjust wheel bearings as lutructed ullder Wheel Bearl.nc Adjustment.

lubricate king pin bearings w1Gl grease specJfied in Seetlon 1050.

to 100-120 foot-pounds (135-162N m) and mat.a new cotter pin.. 7.

If a new epiDdle baa been 1nBtalled, install .. new spindle Mal with seal Up

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:5021-6

REPLACING KING PIN BEARINGS 1.

spindle. The bearing should be flush with the bottom of the bore.

Remove spindle as instructed under Spindle and King Pin.

Use a suitable driver and drivetbebearing(S) from the axle. Drive the upper bearing toward bottom of axle and lower bearing toward top of axle.

Install the upper bearing with the number stamped in end of bearing away from the

Install the lower bearing wiU::J. the number stamped in end of bearIng away from the spindle. The bearing Should be .255" (6.477 mm) below the top of the bore. Then install new seal with lip up on top of the bearing.

Install spindle as instructed under Spindle and King Pin.

FRONT AXLE Removal 1.

Raise front wheels high enough. so axle can be lowered out of the frame and block machine tn place. Then raIse loader bucket above bead level and block in plane with lift cylinder stops.

Disconoect bose from steering control valve at each cylinder and plug all openings with clean caplugs. No other hoses need to be dlSCOWlected.

until centered in yoke. Press or drive axle beam buShings into place until fluSh with the front and rear surfaces of U::J.e axle. Failure to posItion axle buShings as instructed will result in lack of lubrication and early wSbtng or pivot pin failure.

Installation

Remove snap ring and wasber from rear

Place axle under frame and raise into frame. Align pivot pin boles in fame and axle.

Apply a liberal amount of grease on one side of each large wasber and position waShers between frame and axle and front yoke.

Coat pivot pin with oil and drive pin into place with a brass hammer.

Secure pivot pin in place with wasbers and snap rings. Lubricate axle bushings with grease specUied in Section 1050.

Connect boses to steering cylinders.

H tie rod was dropped, attach tie rod to spIndle arm.. Torque nut to 100-120 foot,pounds (135-162 N m) and install new cotter pin.

Start engine and run at low idle. Turn

ot pivot pIn. 4.

Jack up one side of axle just enough to remove weight from pivot pin.

Use a brass rod as a driver and drive pivot pin toward front of macbine.

If pivot pin is difficult to remove, drop one tie rod end, remove snap ring and wasber from front of pin and drive pin toward rear of macbine.

Prevent axle from binding in frame and lower wheel to floor. Roll axle away from machine.

Pivot Bu.hing Installation Three b.Uihings are used in the front axle; one in the front yoke and two in the axle beam. Press or .drive front yoke blShing into yoke

steering wheel slowly through several complete turns to bleed air from the steering circuit.

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5021-7

TOE IN ADJUSTMENT The toe in at the front of the wheels should be O-l/S" (0-3 mm). Measurements are taken at the front and rear of the tires to determine the amount of toe in. Adjustment Is made by turning the tie rod at the rear of

Lower machine to the floor and position the wheels straight ahead.

the axle.

Measuring Toe In

Measure the distance between the scribe marks at the front and rear of the tires. The measurement at the front of the tires should be equal to, or up to 1/8" (3 mm) less than the measurement at the rear of the tires,

Raise front wbeels unW they clear the floor.

Using a Sharp pointed instrument beld securely 1n one position, turn a wheel and scribe a fine Une around the center line of the tire Repeat for the other

Adjustment 1.

Loosen tie rod end C1attlls.

Turn the tie rod as -required to increase or decrease toe in. Then tighten each clamp.

wheel.

H(ASURfllEN'T 8 KIST BE EQUAl TO. aI

1/8" (l.2 rm) LESS THAN MEASUREMENT A WIT~

THE WHEELS STRAIGHT AHEAD

1. 2. 3.

SCRIBE Ko\AA AAOUHD CENTER CENTER OF TIRE TIE ROD TIÂ£ ROD CLAMP SOlT MUST SE OYER surr IN TIE ROO. CLAI1P BOLTS SHOULD AlSO BE INSTALLED FROH THE FRONT ~D BE 0tI TOP Of TIE ROD 751111

Figure 3 - Toe In Adjustment

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Section

6202 POWER SHUTILE AND TORQUE CONVERTER MAINTENANCE. OPERATION AND TROUBLE SHOOTING

J I Case A Tenneco Company

C. E. Dtv. 9-66015 _ N u ......... .

February 1976

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6202-2

TABLE OF CONTENTS SpecHlcations • . . . . . . . . . . . . . • . . • . • • • . • • . . . . . . • . . . . . • • . . • . . • • • . 6202-3 Maintenance . • . . . . . . . • . • • • • • • • • • • • • • • • • • • . • • . • . . . • . . . . . . . . . • . 6202-3 OU Level Check

. . . • . . . . . • . . • . • . . . • . • . • . • . • . . • • • • • • . • • • • • • • 6202-3

011 Drain . • • • • • . . . . . • • . . • • • • • . . . • . . . . . • • • . • . • . . . • . . • . . . • . 6202-3

FUling Power Shuttle and Torque Converter • • • • • • • . . • • . . • . • • • • • • • . .. 6202-3 Power Shuttle Operation .......••••.•••.•••.•.•.•••••••.••••••.•. 6202-4 General .....•••••...•.•••••••••••••••••.•••.•.•.•.•..•.. 6202-4 Power Shuttle in Forward

. ...

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6202-6 6202-7

Power Shuttle in Reverse

Power Shuttle In Forward, Clutch CUtout Solenoid Actuated . . • • • • . • . . . . . .• 6202-8 Trouble Shooting with a Pressure Gauge. . . . . • . . • • • . • • . . • • . . . • • • . • . • ••

6202-10

Pre-Test Checks ••••. ~ ••.•••..•••.. .. •••••• ~ • • • • • • • • • • • • .•

6202-10

Test No. I - Pump (Main Une) Pressure. . . . • • . . . . . . . . . . . • . • . • • . ..

6202-10

Test NO. 2 - Forward and Reverse Clutch Pre ssure . ..•.••• •• ••••••••• 6202-10 Test No.3 - Converter OUt (Cooling Circuit) Pressure. . • • • • . . • • • . • • • ••

6202-10

Interpreting Test Results. . . . . . • • • • • • . . . . . . . . . • . • • . • • • . • • • • • ••

6202-12

Trouble Shooting Chart . . . . . . . . • . • . • . • . . • • . • . . • • . • . • . • . • • • • • • . •.

6202-14

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6202-3

SPECIFICATIONS Oil temperature for test purposes . . • • . • . . . . . • , .. , .. ... Temperature gauge needle in middle green zone on gauge. Pump (ma.1.n line) pressure Engine at low idle and oil at specified temperature . • . . . . . . . . . • 65 psi (448 kPa) minimum in Neutral Engine at 2000 rpm (rimin) and 011 at specified temperature ...• ,., .••....• 130 psi (896 kPa) minimum in Neutral Torque converter out (cooling circuit) pressure . . . . . . . . . . • . 30 pst (206 kPa) or less. engine at 2000 rpm (r/min) Specified oU , . . . . . . . . . . . . • • , •.•.• , . , • , . , ••. , •• , .•••.... Case TCH Fluid Alternate 011 .. , . . . . . . . . . . . . . . Dexron or automatic transmission aU type A, suffix A. Shuttle 011 capacity .. , , . , ... , , , • , . , ....• , , ••.••• 2-1/4 U.S. quarts (2.1l1ters) Torque converter capacity . . . . . . . . . . . . . . . • . . . . . . . . 5-1/2 U.S. quarts (5.2 liters) Total system capacIty (approx.) •• , . , •••••••.. , . , . . . 8-1/2 U.S. quarts (8 Hters) Service speciftcat10ns . . . . . . . . . . . . . . . . . . . • . . . . . . . . • . . . Refer to Section 6210.

MAINTENANCE Oil Level Check The oil Should be checked after every 50 hours of operation or once a week, whichever occurs first. The oil leve l must be checked with the

on at operating temperature.

filter screen. The screen is held in place by ltLe f1t of an O-ring. Clean these parts in cleaning solvent and dry with co~resBed air. Check the condition of the O-ring and pan gasket and replace parts as required. Install O-ring aD filter screen tube and install screen. Place gasket on oil pan and install pan, and install drain plugs in pan and converter. Install plug in bottom of flywheel/converter hOUSing.

Park machine on a level surface. apply parking brake, place transmission in 4th gear and Shuttle in Neutral. The dipstick has an expandable rubber plug. Turn handle counterclockwise several turns and remove the dIpstick. With ltLe engine running at low idle and the dipstick pushed all the way In. the 011 Should be between the L and F marks on the dipstick. Add oil whenever the 011 level is at the L mark or lower.

Filling Power Shuttle and Torque Converter

Oil Drain

Have on hand 8 U.S. quarts (7.5 liters) of Case TCH Fluid.

Add three U.S. quarts (2,8 liters) to ihe shuttle. Have the remaining oil ready to add to the shuttle.

Start engine and run at low idle and immediately add the remaining oi1.

Shift the Shuttle to Forward and Reverse to f111 the c lutch cylinders and all internal passages.

Wben the all is at~rat1ngteII{lerature, check oil level and add all as required.

The oil must be drained and the filter screen cleaned after every 1000 hours of operation or once a year. whichever occurs first. H time permits, warm oU to operating temperature before draining. Park machine on a level surface and apply the parking brake. Remove plug from bottom of flywheel/converter hOUSing. H the converter drain plug is not visible, turn engine over as required to position plug over opening. Then remove converter and Shuttle drain plugs and drain the oU. Remove shuttle oil pan and remove the

NOTE: Do not deviate from this procedure or cosUy and unnecessary damage may result.

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6202-4

POWER SHUTTLE OPERATION General The power shuttle is a torque converter driven forward/reverse transmission that allows the operator to change directions without bringing the machine to a complete stop. Shifts to change direction must be made at engine speeds below 1500 rpm (r/min) toprevent unnecessary damage to the power shuttle. The power shuttle consists of a planetary gear set, multiple disc forward and reverse clutches, control valve, pump and the necessary internal passages and external fluid lines.

not required for lubrication or clutch application flows from the control valve totbe torque converter relief valve which maintains converter inlet pressure and diverts any excess oil to the shuttle oil pan. The front bearing is also lubricated by oil at converter pressure. on from the converter is directed to the oil ccoler and back to the oil pan. A solenoid controlled clutch cutout function is built into the control valve and is discussed on page 6202-8.

With the control valve in Neutral, Figure 1, oil flow from the pump is blocked at the

Refer to Figure 1. Thecresenttypepump pumps 011 to tbe control valve and regulator valve built into the control valve. The regulator valve maintains system pressure. The 011

control valve. on continues to flow to the torque converter and through lubricattonpassages in the shuttle case and input and output shafts.

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6202-5

_ SUCTION OIL _ _ RETUIt~ OIL PIC-I? FLOW

ERT

PRESSURE AND FRONT

DEAA I I L1JBR!CATlON STATIC OIL

f: 1,,"",X':':->lX'»

f: I 1

...1

+ I

1 1

1 1r

tl I 1

1 1

1.1.

--r.l 1 I I

•.:. _____ + ---..I

1 1

I I

1 I

L _______ . . ------------------~------- . . 1. 2. 3.

INT ERNAL PASSAGE FORARD CLUTCH FEED REVERSE CLUTCH FEED

4. 5. 6.

OI L COOLER TORQUE COtfV EHTER PUMP

7. 8. 9.

CONTRO L VAL VE REGUL ATOR VAL VE CONVE RTER RELI EF VALVE

Figur e 1

10 . 11 . 12 .

---J

TO OIL PAl PLU NGER SPOOL

751608

6202-6

Power Shuttle in Forward With the contr ol valve in the forward position, oil at system p r essure flows from the ontrol valve through passages in the shuttle case an output and input shafts to for ward clutch cylinde r. As pressure in the cylinder increases. the pi ston moves the clutch spring. The movement of the spring create s a lever action which forces the forward clutch discs

together. The fric tion discs are secured to the clutch hub a.nd the steel discs are secured to the r ing ge ar. The appl1catio of the forward clutch locks the input shaft and ring gear together. This in turn prevents the pinion gears fr om rotating and locks til input shaft, r ing gear and output shaft together causing them to rotate as a one piece shaft.

_ SUCTION OIL _ _ RETURti OIL

PUl4P Fl O\ol PRESS URE AND FRONT _ . BEAAIIIG l UB RI CATI ON -... STATIC OIL CON~£RTER

., I

I I I I

I I

t:I.!. _____ + ___ • I :~ __ ~ ____

T--.t

I .II

_________________________

1. INT R Al PASSAGE 2. FORWARD CLUTCH FEED 3. REV ERSE CLUTCH FEED

4. OIL COOLER 7. 5. TORQUE CONVERTER 8. 6. PUMP 9.

CONTROL VALVE REGULATOR VALVE CONVERTER RELIEF VALVE

Figure 2

I I ~ ___ J I

10 . TO OIL PAN 11. PLUNGER 12. SPOOL

751609

6202-7

Power Shuttle -n Reverse With the control valve in the reverse position, on at system pressur e flows from the control valve through a passage in the shuttle case to the adapter and into the reverse clutch cavity. As pressure in the oavity increases, the piston pushes against the pressur e plate Which in turn pushes against the clutoh discs and looks them to-

gether. The steel discs are secured to the Shuttle c ase and the friction discs are secured to the ring ge ar. With the clutch discs locked togethe r the ring gear cannot rotate. However. the rota.tion of the tnput shaft c auses the pinion gears to rotate on their shafts which in turn causes the pinion cage/ output shaft to rotate within the ring gear reve rsing the direction of the machine.

_ SUCTI on OIL _ _ RETURN OIL _ PlnolP F L O~j CONVERTER PRESSURE AND FRONT ~- ...,. BEARfNG LUBR ICATI ON .-:0.,">:00 STATIC OIL

i ~x

-~""'-I ~ ~.n~~<-:; I :.;..;..:-x.J

."""'HHIW• .rt..~~~~:aa.~~~ffi

I I

-T-.I

_______+ ___ .1I •I

I I

I I I

I I

L ___ ~ ___ . . --_---~---~----------1. 2.

I NTERNAl PASSAGE

FORWARD CLUTCH FEED REVERS E CLUTCH FEED

OIL COOLER TORQUE CONVERTER PUMP

8. 9.

CDNTROl VALVE REGULATOR V.~L VE CONVERTER REll EF VALVE

FlguTe 3

--+---j 10 . TO OI L PAN 11.

12.

PLUllGER SPOOL

75161 0

6202-8

Power Shuttle in Forward, Clutch Cutout Solenoid Actuated limits the travel of the plunger and spool, is spring loaded to hold the plunger and spool in place for normal shuttle operation and is electrically actuated for the clutch cutout function.

The clutch cutout feature allows power

to be interrupted without manually placing the control valve In Neutral. In some loadIng operations it is desirable to disengage the power Shuttle to make maximum engine power available to the hydraulic pump.

When the solenoid is actuated the springs behind the plunger and spool position the spool in the control valve to block 011 flow to the forward clutcb. At the same time the spool connects the passage to the forward clutch cylinder to an exhaust passage in the control valve to immediately reUeve pressure at the forward clutch.

The clutch cutout solenoid can be actuated by depressing the combined brake pedal (far right) or the right wbeel brake pedal (center pedal) or by depres sing the switch In the floor plate just below the individual brake pedals. The clutch cutout control in the instrument panel Imlst be in the Neutral position to complete the electrical circuit. V/hen the control is in the Drive position, the clutch cutout solenoid cannot be actuated.

Power to the reverse clutch Is Interrupted in the same manner as described for the forward clutch.

The solenoid is screwed onto the control valve a s Ulustrated in Figure 4. Thesolenoid

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6202 -9

. . . . SUCTION OIL _ _ RETURN OIL PUt~P FLOW

~_ BEARING CONVERTERLUBRICATION PRESSURE AND

FRONT

r-----"~s=lrO:~"~I~i~~~;~~

STATIC OIL

I I

+ - .. - .. I

I I

I I I I

tl I I

I •+ _______ +

I --.I

• I I I :L __ ______ . . ______________ ~ __________ . . --~I I 1. 2. 3. 4.

INTER NAL PASSAGE FORIOAR D CL lfT CH FEED REVERSE CLUTCH FEED OIL COOLER

5. 6. 7. 8.

TOR QUE CONVERTER PUt~fl

CONTROL VALVE REGULATOR VALVE

9. 10. 11. 12.

CONVERTER RELIE F VALVE 13. TO OIL PAN PLU NGER 14 . SPOOL

Figure 4

CLUTCH CUTOUT SOLEN OI D ACT UAT ED . PLutIGC: R (ll ) AP.'{) SPOOL (12 ) ~[FT E D TH IS DI RECT ltlN.

751611

6202-10

TROUBLE SHOOTING WITH A PRESSURE GAUGE NOT.; A check will be found at the end of this section that can be copied on any type of copying machine.

Pre-Test Checks

reading. Increase engine speed to 2000 -rpm (r/min) and record pressure gauge reading.

Test No.2 - Forward and Reverse Clutch Pressure

These checks must be made before_Dl.II..k_ iDg the following pressure checks.

Pressure gauge installation is the same as Test No. 1.

Be sure parking brake is applied and four speed transmission Is in Neutral.

Check shuttle oil level as instructed in this section.

Perform stall checks as instructed in Section 2050 to be sure the problem is in the power shuttle (or torque converter).

Place power shuttle in Forward and check clutch pressure with the engine running at low idle and at 2000 rpm (r/min). Record pressure readings.

Place power Shuttle in Reverse and Check clutch pressure with the engine runnIng at low idle and at 2000 rpm (r/min). Record pressure readings.

Check to see that the shuttle control arm Is properly positioned. The steel detent ball should be seated against the control _arm in each position. Adjust linkage and/or free up detent ball as required

Test No.3 - Converter Out (Cooling Circuit) Pressure 1.

Remove the 118'1 pipe plug from the adapter at the front of the shuttle, Figure 5, and connect a pressure gauge that will acurately indicate low pressures.

Be sure parking brake 1s applied and the Shuttle and four speed transmission are in Neutral.

Start engine and run at 2000 rpm (rl min). Check and record pressure with the shuttle in Neutral, FOI'Wud and Reverse.

Test No.1 - Pump (Main Line) Pressure 1.

-2. 3.

Check to see if shuttle oll should be changed (normal maintenance).

Remove the 3/8" pipe plug on the tq) rear of the shuttle and connect a 0-600 psi (0-2136 kPa) pressure gauge to the open port, Figure 5. Apply parking brake and place four speed transmission in Neutral. Start engine, run at low idle and observe pressure gauge and record the

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6202-11 .1

" REt. ' .... T 110.

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.1.22190 PUltCllASE LOCALLY 220-221 .1.21510

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6202-12

Interpreting Test Results Pressur" Indication Low pump (maiD line) pressure.

Poss:.ble Cause and Repair Sticking regulator valve or broken regulator valve spring. Remove control valve from shuttle case and remove regulator valve. Check for broken or weak spring or foreign material that may cause valve to stick. Remove control valve with Shuttle installed. IT necessary, loosen the two rear engine mounting bolts and raise rear of Shuttle slightly so control valve will clear boss on frame. Worn pump. The shuttle must be removed to replace the pump. Do not declare the pump at fault unless the forward and reverse clutch pressures are equally low.

Low forward clutch pressure.

A low idle pressure reading 25 psi (172 kPa) below the low Jdle reading in Test No.1 or a 2000 rpm (r/min) pressure reading 10 psI (69 kPa) below the 2000 rpm (r/ mln) reading in Test No.1 indicates leakage past the metal andl or Teflon sealing r ings on the input and/ or output shaft, or leakage past the clutch cylinder O-rings. Another source of leakage but very unlikely, 1s the oil supply tube or cup plug in the input Shaft. Remove power shuttle and disassemble as required for repair.

Low reverse clutch pressure.

A pressure reading at low idle or at 2000 rpm Cr/ min) 5 pst (a4 kPa) below readings at the same speeds In Test No. 1 indicate leakage past the O-rings on the reverse clutch piston. Remove power shutUe and disassemble as required for repair.

High pump and clutch pressure.

A pressure reading at 2000 rpm (r/ min) considerably higher than obtained in Test no. 1 indicates improper operation of the regulator valve in the control valve. Remove control valve and check for cause. If necessary, loosen the two rear engine mounting bolts and raise rear of shuttle slightly so control valve can be removed.

Pump pressure as specified. no forward or reverse clutch pressure.

Clutch cutout eolenoid not operating properly or cutout spool in control valve Is stuck. Check solenoid first. If solenoid is not the proble m, remove the control valve, dIsassemble and check for c ause. See preceding paragraph concerning control valve removal.

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6202_13

Pressure Indication Pump pressure as specified. no forward or reverse clutcb pressure (Cont'd)

High converter out (cooling Circuit) pressure.

Low converter out (cooling circuit) pressure in Neutral.

Low converter out (cooling circuit) pressure with Forward or Reverse clutch applied.

(

....

Possible Cause and Repair Another possible cause could be a faulty clutch cutout switchj brake pedal or foot q>erated. A pressure reading considerably bigher than

specified is an indication of a restrlcUon in the oil cooling circuit. Remove 011 cooler. connecting hoses and tubes and Check for restriction. A sligbUy low pressure reading is of Uttle con-

cern. However, the pressure will drql as PUIq) volume falls because of 'Near. If the reading Is extremely low and putnp (main line) pressure is as specified. it indicates a damaged converter and replacement of the converter. A considerably lower pressure reading with a clutch applied in comparison to converter out pressure In Neutral indicat~;s a clutch circuit problem. At the same Ume. Test No.2 should also Show low pressure and clutch circuit problem.

or .-

,, " J

• •

•

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6202-14

TROUBLE SHOOTING CHART NO'IW: The following problems andllossible causes are not Hsted in order of importance or occurence.

PRO,,- LEM

POSSmLE CAUSE

REMEDY

External 011 leak

Adapter to shuttle case cap screws loose.

Remove Shuttle. Check for damaged gasket and tighten cap screws.

all line connections loose.

Tighten as required.

Damaged or worn control valve a-ring.

Remove contrcl valve and replace O-ringâ&#x20AC;˘

Loose control valve cover or damaged ga8ket.

Replace cover gasket if necessary and tighten cover cap screws.

Worn or damaged rear seal.

Replace seal.

Loose bearing retainer cap screws or damaged gasket.

Replace gasket as required and tighten cap screws.

Damaged torque converter.

Replace converter.

Regulator valve in control valve stic1d.ng.

Remove control valve, disassemble and check for oause.

Broken or weak regulator valve spring.

Remove control valve, disassemble and repair as required.

Low oil level.

Pill to pr~er level.

Worn pump.

Remove shuttle and replace pump.

Regulator valve in control valve sticking.

Remove control valve, dis assemble and cbeck for cause.

Internally or externally plugged oil cooler.

Unplug oil cooler as required.

Low oU level.

Fill to the proper level.

Operating at converter stall.

~erator' s

-",

Low or no oU pressure

High oil pressure High oil

te~ra-

lure

Control lever does not remain in position pOSition.

High stall speed with tinny sound

Use clutch cutout. Refer to Manual.

Control arm detent spring broken.

Replace spring.

Control arm detent ball corroded and sUcking.

Clean and lubricate ball, spring and bore in shuttle case.

Converter blades damaged.

Replace converter.

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6202-15

580C POWER SHUTTLE CHECK SHEET

....

DATE

OWNER HOURS

TRACTOR SI N

Pre-Test Checks Low idle

rpm (r/mln)

Full throttle

rpm (r/mln)

Converter stall

rpm (r/ mln)

Hydraulic stall

rpm (r/ min)

Combined stall

rpm (r/ min)

Oil Temperature Oll temperature gauge needle Should be in middle of green zone on gauge.

Test No.1 - Pump (Main Une) Pressure At low idle

At 2000 rpm (r/ m1n)

Neutral only

Test No.2 - Forward and Reverse Clutch Forward. clutch Reverse clutch

Test No.3 - Corwerter Out Pressure Neutral

no test

Forward

no test

Reverse

no test

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Section 6210 POWER SHUTTLE

J I Case A Tenneco Company

C. E. Olv. 9-66015 .","",.D . .

February 1976

u.u"

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TABLE OF CONTENTS Specifications . . . . • . • • • . • . • • • • • • . . • • • . . . . . • . • • • • . . . . • • • • • • • . . . •

6210~3

Special Tool . • . • . . . . . . . • • . . • • . . . ' . ' . . • . . . • . . . • . • • • • • • • • • • • • . • . • 6210-3

Servicing the Power Sl:n.tttle . • . . • • • • • . • • • . • • • . • • . • • • • . . . • . • . • . • . . . .. 6210-4 ReInOval . . . • • . . . . • . • . • . • • . . • • • . . • • • • . • • • • • • • . . • • • • . • . . . . . 6210-4

Disassembly . . . . . • • . . . . •

• •.•.••.•.••... -. .•.•••••••••••••... 6210-4

Inspection • • • • • • . • . • . • . • • • • • • • • • • • • • • . • • • • • • • • . . . . . . . • . . . . . 6210-12 Assembly ••••••••••••••• •• " . •• _•••••••••••••••.•.••••••••••• 6210-13 Installation . • . . . . • • • • • • • • • • • • • • • . • • • • • . • . . • . • • • • • • • • • • • . • • . 6210-25

Torque Converter . • . . • . • . . . • . • • • . • • • • • • . . • . • • • . • . . . . . . . . . • . . . . . 6210-26 ReInOval . . • . . . . . • • • . • • . . • . . . . • • • • . • . • • • . • • • • . . . . . . • . . . . . . . 6210-26 Installation •.•••••.•.•.••

! • • • • • : . . . . ....

: .•••••••••••••••••••

6210-26

•

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6210-3

SPECIFICATIONS Power shuttle dry weIght (approx. )

Torque converter dry v.-eight (approx.) Sprillgs Regulator valve

Free length (approx.) 2.668" (67.767 mm)

Plunger

113 pounds (51.3 kg! 32 poundS (14.5 kg) Compressed length (approx.) 2.073" at 74-82 pounds (52.654 rom at 33.6-37.2 kg)

.86" -at 2.7 pounds

1.45" (36.83 mm)

Clutch cutout

.686" (11.424 rom) 1.25"

Pressure plate

(31.75 mm)

Special torques Rear bearing retainer cap screws

. . . . . .. . . . . . . .

(21.844 mm at 1.22 kg) .453" at 1.9-2.2 pounds

(11.506 mm at 0,86-0.99 kg)

1" at 13.5-16.5 pounds (25.4 at 6. 12-7.48 kg)

.... . . . . . .

40-50 foot-POWlds (54-67 N m)

Output flange nut . • . . . . • • • • . . • . . • . • • • . . . . • . • . • • . . . . . 75-85 foot-pounds (102-115 N m)

Adapter cap screws . • ••.•.•.•••....•••.•....•.•• • .... 27-37 foot-pounds (36-50 N m)

CO'\'erter support flat head screw .... • ..•••.•••.•••.•••.•• 25-35 inch -pounds (3-4 N m)

Pump mounting cap screws ••.•.••.•..•••......•••..•... 17-22 foot-pounds (23-29 N m)

Shuttle mounting cap screws

.........•.•..•••••.•.•.... 45-55 foot-pounds (61-74 N m)

Flex plate to converter cap screws •••.••••••....••..•..•.. 28-32 foot-pounCe (37-43 N m)

Flex plate to flywheel cap screws

•..••••.•....•.••••.•... 13-15 foot-pounds (18-20 N m)

Universal

joint

cap

screws . . . . . . . . . . . . . . . . . . . . . . • . • . . . . 20-24 foot-pounds (27-32 N m)

SPECIAL TOOL The special tool illustrated in Figure 1 must be used whenever the flex plata is being attached to the torque converter. The tool centers !:he flex plate on the converter. Order part number D51651 from SPS in the usual manner.

Figure 1

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6210-4

SERVICING THE POWER SHUTTLE Removal l.

Remove plug from bottom of the flywheel bousing. Turn engine over until drainplug in torque converter can be see in bole. Remove the shuttle and converter drain plugs and drain oil. Approximately 8 U.S, quarts (7.5 liters} will be drained.

Disconnect drive shaftfrompower shuttle output flange and remove the drive shaft.

Disconnect oll cooler lines at the power sbuttle. Remove shuttle dipstick anddisconnect fill tube from shuttle.

Unplug solenoid wiring harness. Disconnect wir ing from temperatw-e sender and neutral switch. Remove groWld wire from shuttle valve cover cap screw.

Disconnect 1 inkage at shuttle COil trol arm.

Place transmlssion jack under shuttle and remove the six shuttle mounting cap screws, three on each side.

Figure 2 4.

Place pump on bencb with converter support down and remove flathead screw from rear of pump. FIgure 3.

-..

Move shuttle straight back using care not to damage tile torque converter. Lower shuttle to the floor. NOTE: Whenever the clutch cutout solenoid is removed. handle the shuttle carefully. If the control valve plunger is pushed in too far, internal damage will result.

Disassembly 1.

Before dIsassembling the shuttle, remove all traces of accumuluted dirt.

Figure 3 2.

Remove the oil pan and filter screen. The filter screen tube is held by the fit of an O-ring, Remove the four pump mounting cap screws, F'lgure 2. Then remove pump and gasket from adapter.

a. b.

Lower pump straight down. Before

housing and gears

removing the gears mark

each gear face to assure that the gears will be properly installed.

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6210;:p-a ~. plate !

from fallffig and cauSing needl.e.s damage.

1. MARK GEAR FACES BEFORE REIDVING

Figure 4

5.' ..,'Remove seal from pump houa1Jig and ;-'d18Card &ea!. 6......Before removing the adapter check iDput shaft end play with a dia!1ndicator;- End

Remove ~ver88 olutcb. prea~ plate 'from adapter or Shuttle case. ~l-

Remove the four cap screws which secure

Apply,.. co~re8sed a1r to clutch supply bole in lhe In removing piston from 7. nten remove

the adapter to the ShuWe case, FJgw'e 5.

aDd quad

pl ..y s hould be between .010" and .086" oJl (0.25-2.18 nun). If end play is .greatln' -- Ulan specified, chedc. for worn- tbrust

Wl.sbers and mating parts,

'1 ,

Figure 6

r1»& from

Then remove the adapter and reverse

4 iston

I.Ssemhly. Figure 6. U~ care

when removing the adapter 1.6 the re:ver88

clutch pressure rever_ piston.

8t1ck~ to -the

pre'" sur:e.

1. REVERSE CLUTCH SUPPLY HOLE

1. CAP SCREWS

FIgure ,

Re~ ~.• ·reVh'se

Figure 5

~..

olutcb spr.b:iir8. dowel

pins aDd clutch discs. Figure S.il-

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6210-6

Figure 10

2. DOWEL PIN

1. SPRING (11)

Figure 8 11 . Lift the forward clutch assemblyfrom the

shuttle case . Then remove tbrustwasher from either the rear of the clutch assembly or the pinion cage as oU may cause it to stick toeltherpiece, Figure 9.

13. Place forward clutch assemblylnapress with the input shaft up. Press shaft from clutch. Do not allow Shaft to fall to the floor. A soft hammer may also be used to dr ive Shaft from clutcb.

14. Place forward clutcb assembly on bench with clutch cylinder up. Remove cylinder retaining ring and remove cylinder/ piston assembly from ring gear. The cylinder 1s a I ight press fit in the ring gear. Press or care-

NOTE:

fully drive cylinder

from ring gear.

1. THRUST WASHER

Figure 9 12. Remove thrust washer from face of for ward clutch cylinder and remove bearing retaining ring from input shaft, Figure 10.

Figure 11

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6210-7 15. Remove the clutch spring. Figure 11, and front pressure plate retaining ring. Figure 12, from ring gear. Remove front pressure plate, clutch discs and rear pressure plate. Then remove rear pressure plate retaining ring.

Shaft out of hub. Then remove Woodruff key from shaft. .-;,-

. -;~ ~.'

Figure 14

18. Attach a suitable tool to the output

flange and remove flange retaining nut. Tben remove flange from output shaft. Figure 12

16. Unlock the two large diameter sealing rings on the input shaft. Use a suitable pair of pliers and remove the sealing rings. Figure 13. Then remove the Teflon sealing rings

from opposite end

of shaft.

Figure 13

17. Remove the forward clutch hub retaining ring, Figure 14. Place shaft assembly in press with long end of Shaft up andpress

19. Pull pinion cage/output shaft assembly from shuttle case, If necessary. use a soft hammer and tSF- end of shaft to aid In removal.

20. DO NOT disassemble the pinion cage unless inspectJon reveals badly worn or damaged parts and a lathe and qualified machinist are available for oU collector ring installation. The aU collector ring must be spin formed to the pinion cage and be leak proof. If disassembly is necessary:

Remove oil collector ring from rear of pinion cage. Damage to the ring from removal will prevent using the ring again.

Remove the pinion shaft retaining pins. Then press the pinion shafts out of pinion cage. '!bere are fortyeight needle bearings and three spacers for each pinion.

Remove pinion gears and thrust washers from pinion cage. Keep mating gears and thrust washers together if they are to be used again.

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, ••

--1. INNER PIt/lOtI GEAR .. , (PLAIH TEETH) ~. OUTER PINION GEAR (NOTOfEO TEETH) 3. PINION SHAFTS STAAPED WITH

PINION SHAFT RETAINING PIN PAIR OF PINIOli- GEARS

8. NEEDLE BEARINGS

(48 PER PilliON GEAR)

9. OIL COLLECTOR RiNG

IN OUTER PUIlOH GEARS

4. NEEDLE BEARING SPACER ...

PINION SHAFT

7. THRUST WASHER (2 PER

NUHBER .2. HUSl BE INSTALLED

"-1;

10.

5/16" (7.9 om)

75!6;1

(3 PER PINION GEAR)

Figure 15

• ~, t':~~

"'"

•

',W,

Hl-f: , W_,.:

"'If ~.:

,1"

_~;J<,

,.:~

''411 .or. ,0/;

,',...

..~ . ' .

i~~

......; .. ;~

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~.~;.

U.-

... " -

•

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6210-9 2L Remove needle bearing from bore in pinion cage/output shaft onlyv.11en inspection

1nd1oates replacement. Use a puller that will not d8lOage the bearing bore.

22. Re1llOve reax bearing retainer cap screws and retainer, Remove gasketfromshattle

case or bearJng retalDer. The bearing is

a sUp m in the reWner; remove bearing from retainer.

23. DO NOT remove the s leeve or needle bearing from shuttle case, Figure 16, unless inspection lnd1cates pa.rts replacement.

1. OONTROL ARM

2. DETENT BALL 3. SPRING F1gure 17

1. SLEEVE

2, NEEDLE BEARmG Figure 16

24. Unscrew clutch cutoutsolenoid fromoontrol valve. Remove control arm. Fl.gure 17. using care not to loose steel ball and spr.lng, Then remove spring, and snap ring from control valve, Figure 18.

25. Remove valve cover reta1nlng cap screws , cover , gasket, neutral start cam, and flll tube fitting. Push control valve part way out of shuttle case then 'pull valve fr om case. 26. Refer to Figure 20. Place control valve on a piece of wood and drive the two roll pins out of the control valve, Remove plunger, plunger springâ&#x20AC;˘ .spool and spool spring from the control valve. Remove O- ring from plunger and valve body.

1. SNAP RING

Figure 18 27. Place control valve between two blocks of wood in a machinists vise with the regulator valve up. Then compress regulator valve spring in a press and remove the snap ring. Refer to Figure 20. Remove valve from press and remove the spring seat, spring and regulator valve the valve body, Do not remove expansion plug from bore in control valve.

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· 6210-10 Seal '" .. _ Pump Housing .' BuShing 4. Drive Gear 5. Driven Gear· 6. · Converter Support 7 ' Gasket 8. Adapter 9, Gasket 10. .Reverse Clutch 11. Piston 12. .Quad RIng 13. Pressure Plate 14. Dov.-ei Pin (3) 15. Sprin3: (11) 16. Friction Disc (3) 17. li.tgged. Disc (2) 18. Forward Clutch 19. Snap Ring 20. Ball Bearing 21. Thrust Washer 22. Cyltnder 2S. Piston 24. Clutch Spring Bearing Rin3: 25. D-ring 26. Clutch Spring 27. FrontFressure Plate 28. Friction Disc (7) 29. Steel Disc (6) 30. Rear Pressure Plate Sl. Clutch HUb S2. Ring Gear 3S. Select Fit Snap Ring 34. Metal Sealing Ring 35. Input Shaft: 36. Woodruff Key 37. Teflon Sealing Ring 38. Forward Clutch Supply Tube 39. Cup Plug , 40. Bronze Thrust WaSher

41. Pinion Cage/ Oltput Shaft Assembly 42. Pinion Cage/()Jtput ~aft 43. Needle Bearing 44. Oil Collector Ring 45. Long Retaining Pin 46. Slort Retaining Pin 47. Inner Pinion Shaft (3) 48. outer PInion Shaft (3) 49. Outer Pinion Gear (3) 50. Inner Pinion Gear (3) 51. Needle Bearing (48 per gear) 52. Bearing Spacer (3 per gear) 53. Thrust Washer (2 per gear set) 54. Oil Baffle 55. Shuttle Case 56, Breather 57. Clutch Cutout Solenoid 58. Control Arm , 59. steel Ball (detent) 60. Detent Spring 61, PIWlger ~ 62. 'Plunger Spring 63. Clutch Cutout Spool . 64. Cutout Spool Spring 65. Roll Pin 66. Control Valve 67. Expa;.'sfon Plug 68, Regulator Valve 69. Regulator Valve Spring 70. Spring Seat 71. Neutral Star:. Cam 72. Valve Cover

2. S.

73. Neutral Start Switch l. ...

••

Filter Screen Oil Pan Sleeve Bearing Retainer 78, Yoke 79. Ws..sber 80. SeH- lock1ng Nut 74. 75. 76. 77.

•

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621 0- 1

Che ck h ou s ing for cracks, excessi e wear. pitting and scoring.

Check converter support for signs of crac k s and we ar from gear s. Also check

bushing for wear, pitting and scoring. Adapter 1.

Ch e ck adap ter fpr c racks and wear in the piston area. Make sure all passages in adapter are open an free of for Ign matter. Als o che ck bushing for w ~ ar. pitting and scoring.

Reverse Clutch I.

O-RIItG

2. ""

PUJl1Gf"R

5. 6.

SPOOL SPRING VAl.VE !OOY

Pl Uft{;[ R 4. SPOOl

7. SP~ INti

Check reverse cl tch piston for we ar , scoring and nicks and bur rs on the inside and ou t s ide diameters.

Check pressure plate for wear and scoring on the rear (clutch disc) fa c e.

Check the pressure p l ate springs for dis tortion and signs of cracking. The free height of the sp ri ngs should be very close to being equal.

Check dowel pins for we ar.

Check t he rever e clutch ( iscs for weal' On f aces and teeth. All the discs should be flat.

ROll PIN

8 . EXPAHS10tj PLUG 9. REGULATOR VALVE 10 . REGUlATOR VALVE SPR ING 11 . SPRING SEAT 751615 12. $.HAP RI HG

F igure 20

28. Remove baffle fr om shuttle case. The baffle 1s a snap fit on bos ses in the case. Push be.ffle off bosses and remove from case.

Inspection Pump 1.

Only the fro nt seal is a serviceable part. If other parts of the purnp should require replaceme nt, the complete pump mu st be rept ced . Clearance in excess of .0025" (0 .063 rom) between the gear faces and pump housing and converter support will affect pump ou tpu t at high oil tempe ratures. Therefore, a pump th at is worn to the point of rep air m " look good. If oU pressure was low in Neutral and Reverse and all valves are wo rking properly. the pump should be replaced.

Forward Clutch 1.

Check forward clutch cylinder for wear and scoring in the piston and i nput shaft bores.

Check the clutch piston for we ar an s coring on the ins ide and outside diameters . Also check to see that blee hole in pis ton is ope n, Figure 21.

Check the f r ont and rear pressure pl ate faces for we ar and scoring. Al so check teeth for wear .â&#x20AC;˘

Check the friction discs for wea r, met al build up and discoloration due to e xcessive heat. If the discs are smooth or nearly s mooth they should be replaced. All friction discs should be replaced at replaced at the same time.

NOTE:

Check gears for exce iva wear, nicks on gear teeth and s cored faces. Also check bushing in drive gear for wear, p itting and scoring.

6210-13

Check for excessive plnlon gear end play between thrust wa&b.e r s .

Check needle bearing in output shaft for flat spots, gallings. etc. U no defects are found and the needles are free of ex cessive play and remain in the cage there is no need to r eplac e the bearing.

Check spline s on output Shaft (or cracks and burrs.

Other Components

Figure 21 5,

Check the steel discs for wear, scoring, metal build up and discoloration due to exce s sive heat. The disc should be sl1gbtly coned but not warped. All steel discs sbould be replaced at the same time.

Discard all seals, a -rings , metal sealIng rings and Teflon seaUng rings.

Check throst washers for wear and scoring.

Check Shuttle case for cracks and other damage. Make sure all passages are open and free of foreign matter. Check needle bearing in case for flat spots. galling, etc. If no defects are found and the needles are free of excessive play and remain in the cage there is no need to replace the bearing.

A.sembly 6,

Check the c lutch spring for signs of cracking and los s of cone.

Check c lutch hub for wear. Also check keyway for we ar.

Check ring ge ar for 'Wear and damage that could result in failure.

Check input shaft for wear and scoring in the bearlng contact area. Check drive gear teeth for we ar, nicks and other damage . Make sure oUpass ages axe open and free of foreign matter.

Pinion Cage/ Output Shaft Assembly NOTI!: Dis asse mble pinion cage only if Inspectlon reveal s de fective parts and a l athe and qualif1ed machini st are avaHable.

cÂˇ

Check pinion gears for free rotation. Also check gear teeth for nicks and scoring.

1/8"!. l13t" (1.% !. 0.8 _ 1 CUP P\.tJG (SHOUlD RAIt[lY MEED ItE PI.AW IG)

Figure 22

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6210-1:4

H the sleeve was removed from the rear of "the 'Shuttle case, press in a new sleeve at this time. When the sleeve is seated in the bore it will extend beyond the case about 1/8" (3.2 mm).

Press new needle bearing into sbuttle to the dimension Shown in Figure 22. H bearing bas part .number or other mark:1llgs on one end, press against this end of bearing. case

PoslUon 011 baffle under the two bosses on rear of case as shown in Eigure 23. .)

Figure 24

Press p1n1on shafts with the number 2 stamped on end of Shaft into !:be outer abaft holes. Be sure retaining pin hole in abaft and pinion cage are al1gned. SecUre Shafts in place with retaining pin. "

"~j -

Figure 23

Place front edge of baffle on ledge at front of case and 11ft rear of bame and snap over bosses at the rear of tbecaae, Flgure.24.

HOT.: The next step must be completed on a lathe by a qualifJed

machinist.

U the p1nion cage was disassembled. reassemble as follows!

a..

Coat inside of pinion gears with grease to bold needle bearings and spacer" in place. lDstall m1ddl~ spacer and install oeed.le bearingS (48 per gear) and the outer spacers.

eo"it the smootb side of the thrust wasbers witb grease and place in pinion cage with grooved side toward ~ .gears.'...

Install the gears with notches in and align with the outer p1nion &haft

'ti!elb betw'een thrust washers holes.

.Place remaining pinion gears between thrust washers and press pinion shafts into place. Be sure retaIning pin hole in shafts and pinIon cage are allgned. Secure Sbafts in place with retaining pin.

Place 011 collector on rear of pinJon cage. Place pinion cage assembly in lathe and form the oil collector ring qalnst the pinion cage to form an 011 tight seal. Remove any burrs made during forming.

Press new needle bearing into output shaft to the' dimension Shown in Figure 15. H bear~g has part number or oth~r markings on one end, press agatnst this end of bearing. ~ â&#x20AC;˘

Place pinion cage/output shaft aSS17mbly on a block 5" (127 mm) in diameter and 2-7/8" (73 nun) bigh with the shatt up. Then place these parts in a press.

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6210-15 8.

Lower Ule shuttle onse over the output shaft. The case should be resting against the press bed

Sbrt

a steel disc In the ring gear. Continue alternating discs until all discs have been installed, Figure 26.

the rear bearing onto the output shl!.ft.. Then use a driver that oontacts both the inner and outer bearing races and press bearing onto Shaft until seated against the sleeve.

10. Press a new seal into bearing retainer until seated against shoulder tn seal bore.

11. Place new bearing retainer gasket on shuttle case. Install bearingretalnerover bearing. Press retainer into place if necessary. Torque bearing retainer cap sorews to specification on page 6210- 3. 12 . Install output flange on shaft and secure in place with washer and nut. Attacb a suitable tool to the flange and torque nut to specification on page 6210- 3.

13. Place ring gear on clean bench with the outside teeth up. Ftgure 23. Then lruitall rear pressure plate with smooth surface up. The rear pressure plate Is recessed on one side.

Figure 26 15. Install front pressure plate in ring gear with 5Dlooth fllCe down, Figure 27.

69!651

1. SMOOTH FACE OF PRESSURE PLATE DOWN 1. Sr-,1OOTH FACEOF PRESSURE

PLATE UP Figure 25 14. Lubricate the clutch discs with clean Case TCH Fluid. Place a friction disc and then

Figure 27

16. Install the front pressure plate retaining ring. Figure 28. Milko sure the prcper ring is I.nÂŁtalled. This ring measures .090"-.093" (2.29 - 2.36 rom) t.hickandbas a free diameter of 5-19/32" (142.1 mm).

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621{).o.16 t.._ -,.

o Figure 30 19. Install D-ring in groove in forward clutch cylinder hub, Figure 31. FIgure 28 17. Place forward clutch spring in rIng gear with fingers, up. Figure 29.

o Figure 31'

1. INSTALL SPRING WITH FINGERS UP

Figure 29 18. LubrIcate new forward clutch piston quad ring and Install quad ring in groove in pIston. Figure 30. Then install clutch spring bearing ring in groove in piston. _Be sure ring 1s seated in groove.

FIgure 32

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6210-17

20. -I..llbricate the cylinder wall and bub with clean oil. Start pIston squarely into cylinder and push into cylinder until it bottoms, Figure 32. The pIston can be pressed into the cylinder If desired.

the cylinder bub. Place ring gear and support in press and l1ghtly compress the clutch discs against the front pres~re

plate, Figure 35.

21. Install olutch cylinder Innng gear with pIston toward clutch spring. Then place ring gear assembly in a press and press cylinder into ring gear-untU snap ring groove is visible, Figure 33.

.Figure 34

c â&#x20AC;˘ 1. PRESS 2 . .DRIVER 3, FORWARD CLUTCH ASSEMBLY

Figure 33

22. With the ring gear assembly in the press install the clutch cylinder retaining ring. Make sure the proper snap ring Is installed. This ring measures .074" -.078" (1.88-1.98 mIn thick and bas a free diameter of 5-7/S" (149.2 mm).

23, Place the rIng gear on a fixture that will support the ring gear without contacting

Figure 35

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6210-18 24. With the clutch discs compressed, use a feeler gauge and measure the space between the pressure plate and top surface of the snap ring groove, Figure 35. Record this measurement

:.-

25. Install the necessary select fit snap ring(s). Figure 36, to obtain a clearance of .040"-.065" (1.02-1.65 mm). These snap rings have a free diameter of 511/16" (144.5 mm) and are color coded as follows; green. ,050" -.054" (1.27-1.37 mm). orange. .074"-.078" (1.88-1.98 mm). and white, .096"-.100" (2.44-2.54 mm), The color code is not always easily visIble, therefore, check ring thickness witb micrometer as required. It is sometimes necessary to use two of the thinner snap rings to obtain the proper clearance. Figure 37 27. Install bub retaining snap ring, Figure 38.

.:;

â&#x20AC;˘,

j â&#x20AC;˘

-"'. ...

/~;

,. ,,,

Figure 36 26. Install Woodruff key in input shaft and lubricate bore of fonvard clutch hub with clean oil. Install hub on shaft with the open side away from gear on shaft. Press bub onto shaft until seated against gear.

Figure 38 28. Install two new metal sealing rings in grooves in input shaft. FIgure 39 and lock ends of rings together. Then in-

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6210~l.9

stall new TeOon sealing rings in grooves at opposite end of shaft.

SO. Place Input shaft and ring gear assembly and fixture in a press. Start front bearing onto shaft and use a suitable tool and pre . . bearing onto shaft, Figure 41.

Wltll snap ring groove In the clutcb cylinder bore is exposed.

Figure 39 29. Place the input shaft in a suitable fixture and lower the r1ng gear assembly over the input shaft. Figure 40. DO NOT force the ring gear down as damage to the friction discs may result. When the ring gear is in the proper position the ring gear will be flush with the drive gear. Do not remove this assembly

Figure 41

from fixture.

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Figure 42

1.-

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6210-":W

Install front bearing retaining ring on input shaft, Figure 42.

31.

gear as required to engage the pinion

gears.

32, Install front bearing retaining rIng in groove in clutcb cylinder hub, Flgure43 .

â&#x20AC;˘

1. THRUST WASHER

Figure 45 35. Refer to Figure 46 and install the eleven reverse clutch springs and the three dowel pins in the shuttle case. Figure 43 33. Coat the bronze thrust washer with clean grease and place on front face of the output shaft, Figure 44.

. .... 1. SPRING

2. DOWEL PIN

1. BRONZE THRUST WASHER

Figure 44

84. Pour clean au over the pinion cage and install the forward clutch/input shaft assembly using care not to move thrust washer out of place or damage the Teflon sealing rings. Figure 45. Rotate the ring

Figure 46

36. Lubricate the reverse clutcb discs with clean oil. Place friction disc then a lugged disc in the reverse clutcb cavity. Figure 47. The odd lug must be positioned as

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6210-21

Shown In Figure 4.7. Cont:inlJe alternating clutch dillCsuntil all bave beentnstall.ed..

stalled, the pres8w:e plate will be just about flush with the case. 38 . Install thrust wasber on clutch cyllDder bub and place new adapter gasket Qn the shuttle cue, Figure 48. 39 . Install a new quad ring in groove in re-

verse clutcb pf.aton, Figure 49.

1. 000 LUG. MUST BE INSTALLED ON DOWEL PIN WITH WIDE SlOE OF LUG TOWARD THE BOTTOM.

FIgure 47

37. Place the reverse olutcb pressure plate DO the sprlngs with the smooth [ace up aDd the V-groov-e in the pressure plate aligned "''1th large hole at top of Shuttle cue, F1gure 48. Wben properly in-

Figure 48 40. Install a new D-rlng in groen'e lnadapter

hub, Figure 50.

Figure 50 1. VEE GROOVE

2 . LARGE HOLE

3. THRUST WASHER Figure 48

41 . If busbin, waa removed trom adapter, press -in a. new buahlo .. .attbJa time. Tho split in the busbing must be to tbe right on the borl%ontal centerline of tbe adapter in its installed posltkxl viewed from the rear. Preas bushing In from

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6210-22 the rear of the adapter. The bushing should be flush wIth, to .020" (5.08 mm) below end of bushing bore. The oole in the bushing serves no useful purpose and should be Ignored.

44. Install the four adapter retaining cap screws. Figure 52. and tighten alternately and evenly. Torque the cap screws evenly to specifica.tion on page 6210-3.

42. Lubricate the reverse clutch piston bore and quad rIng with clean oU. Install piston in adapter with smooth face toward adapter. Figure 51. Use the Oat surface of a clean screwdriver blade to help start quad ring into adapter if necessary.

45. Start new seal into pump houslng and press into place untO lighUy seated against Shoulder in housing. FIgure 53.

Figure 51

1. PRESS 2. DRIVER 3. SEAL

43. Lower the ada.pter over the input sbaft and squarely onto the shuttle case. When the pUot diameter of the adapter enters the case. align the cap screw ooles and check gap between adapter and case to assure squareness.

46. Install gears 1npump hous1ngwtth marked surfaces UP. Figure 54.

1. CAP SCREW

1. MARKED SURFACES MUST BE UP Figure 52

F1gure 53

Figure 54

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6210-23

47. 'Pour clean aU over the geus and install the converter support. Secure support in place with flat bead screw, Figure 54. Torque screw to spec1ilcat1on on page 6210-3, Check to see that the gears turn freely. If gears bind, disassemble pump and check for cause.

spring seat on

spring and compress

spring untU snap ring groove is exposed. Then install snap ring and remove control valve from vise. 50, Place spring In end of spool and install spool. spring first. in control valve. Partially cOll:l>ress the spring and drive a new roll pin into the control valve to properly position the spool.

• ;,;-

FIgure 55

48, Coat one side of new pump gasket with clean grease and place gasket on pump. Please pump on adapter and secure In place with cap screws. The long cap screws should be installed in holes with high bosses. Torque cap screws to S(H:IcWcation on page 6210-3.

I)-UN&

PlUNGER

I'LlItGEII SPRI/IG

4. S.

SI'OOl

SfOOL SF'tUJl;

W,lLW( Boor

ROll 'III

t. U'AIIS1OH P\.UG

9. )0. 11. 12 .

~[IOULATDII ¥Al'i£ REGl.U10ll ¥Al.'i£ SPltI'" SPRING SOT S/W' RIIIG 1116»

Figure 57

51. Install new O-xing on plunger. Install 'plunger spring and plunger in control valve. Push plunger into control valve unW 1t extends from control valve about S/S" (15.9 mm); bold plunger In this position and drive new roll pin into control valve to retain and properly position the plunger.

•

Flgure 56

()

2. 3.

49, Install regulator valve and spring in the control valve. Compress spring as .instructed during disassembly. Place

52. Install new O-ring on control valve. Coat control valve with clean oil and install valve in sbuttle case. .Before pushing val:ve all the way in. position valve so notch in valve Is at the bottom, Figure 58,

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6210- 24

Figure 58 53. Install neutral start cam making sure tab on cam engages notch 1n control valve, Figure 59.

Figure 60 56. Install control arm as illustrated in Figure 61. Screw solenoid part way onto control valve and place steel ball between the detent spring and control arrn. Then Ughten solenoid on control valve.

Figure 59

54. Install valve cover with a new gasket and secure in place with cap screws and lock washers. Torque cap screws to specIfioation on page 6210-3.

1. DETENT SPRING 2. STEEL BALL 3. CONTROL ARM

Figure 61

55. Install snap ring in groove at control end

of valve, F igure 60. Then place detent spring in shuttle case.

57. Install new O-ring on filter screen tube and install filter in shuttle hOUSing,

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6210-25

Figure 62. Place new oll pan gasket on housing. install pan and secure in place with cap screws and lock washers.

housing mating surfaces are parallel. Adjust shuttle position as required. 3,

Move the shuttle forward to engage the input shaft, converter support and ~ drive gear with tangs on converter. 1\J.rn the flywheel as required with a screw,.. driver to align splines and drive tangs. If the shuttle cannot be pushed aga.1net the converter bousing. parts are not properly aligned Turn flywheel &8 required. DO NOT force the Shuttle into place; It must slide into place by band or damage will result.

Install the two top Shuttle mounting cap screws wt do not tighten at this time. Then remove the guide bolts and install the four remalning cap screws. Torque the cap screws evenly to specification on page 6210-3 .

.Connect 011 lines to power shuWe.

Install drive shaft and connect to shuttle output flange. Torque cap screw to specHication on page 6210-3.

Figure 62 58. Install fill tube fitting In shuttle case,

(

Installation 1.

7. installing the -power shuttle. make two guide studs by cutung the beads off two 7/16"-NC"X 6" ixllts and cut a screwdriver slot in each side of the converter housing.

Connect CODtrol linkage to control valve control arm.

Install shutue fill tube. Be sure tube bottoms in fitting. U tube is not properly installed, overfilling and unnecessary damage will result.

Set Shuttle on transmission jack and raise into alignment with the guide bolts. -S tart shuttle onto guide bolts and Check to see that the Shuttle and converter

Fill sbutue with new Case TCH Fluid as 1nstructed under Maintenance in Section 6202.

Before

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6210-26

TORQUE CONVeRTER Should it be necessary to service the torque converter, the complete converter must be replaced. Replacement Is necessary because the welded construction of the converter prevents replacement of internal parts.

refer to parts catalog for the proper part. Do not torque cap screws at this time.

Removal 1.

Remove the power shuttle as instructed in this section.

Remove front cover from flywheel/converter housing.

Support the engine with a jack under the rear of the 011 pan.

Remove the rear engine mounting bolts. The flywheel/converter housing weighS approximately 65 pounds (29.5 kg); bave someone available to help remove the housing.

NOTE:

Figure 63 5.

Remove the nut, hardened washers and bolt on each side of the hoUSing. Then remove the h\"Onuts, lock washers and hardened wasbers at the top and remove the housing.

The torque converter MUST be cantered on the flyv,neel within .004" (0.102 nun). Check converter position using a dial indicator positioned against the converter hub. Reposition converter as required and torque cap screws to specification on page 6210-3.

Install flywheel/converter hOUSing. Install hardened washers. lock washers and nuts on studs at top of housJng. Do not tightllll nuts at this "time.

Install the bolts with hardened washers on each side of hOUSing. H a bolt 15 to be replaced, use the bolt specified in the parts catalog. These bolts position the hOUSing relative to the converter. The use of any other bolt could result damage to the converter. pump or pump seal.

Remove the six flex plate to flywheel caps screws and washers and remove converter.

Installation 1.

If the converter or flex plate is being replaced, place converter on bench with converter . hub doÂˇwn. Then place flax plate and reinforcing ring on converter and install two opposing cap screws but do not tighten .

Install alignment tool, Figure 1. over pilot boss on converter with pins in reinforCing ring and flex plate as illusb."ated in Figure 63. Install the remaining cap screws and torque cap screws to specifications on page 6210-3. Attach the converter to the flywheel with cap screws and hardened flat washers. H a washer is to be replaced,

Install hardened washer and rut on each bolt and tighten all four nuts.

Install shuttle as instructed in this section.

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Section 6211 SHUTILE CONTROLS (POWER AND MECHANICAL)

J I Case

C. E. Div. 9-66015

A TIII"N'\8CO COmaany

.............

Febl'Uary 1976

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6211 - 2

L NEUTRAL LOCK 2. WHEN UPPER AND LOWER SHAFTS ARE

ASSEMBLED. POSITION COLLAR TO OBTAIN

l/32"·3/3Z· (0.8 mm_2 mm) SHAFT FREE PlAY.

J. IfoISTAll 8AlL JOIKTS 0tI ROO FlIIGER TIM. TH(II POSITION 8ALl JQIHTS AS SHlI/N AHIl

4. PLACE DIRECTIOIl LEVER 1M I'lEUTAAL LOCk AIIO SHUTTLE CONTROL ARM 11'1 NEUTRAl . AND ADJUST LENGTH O~ ROD ~ REQUIRED. S. SHUTTLE CONTROL ARM. 15l1JI

T1GKTEN LOCK NUTS.

Figure 1 - Power Shuttl e Control inst allation

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6211-3

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, ).

, "\:, I

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I. CIR.E CT IOH COIfT1IOl

2. 1.

AArfG[ CONTJICll t~STAl.l 'Al.l JOlm

ON ROO flN6ER

TIGHT. THEN POSITION 'All JOINTS AS SII(MI A!IO T1GKTOI lOCI( MS.

,. !lEERING COLUMN 8RACkET 5. CC"NECTCR 6. INSTIII.HENT PAllEt

a.[yI~

ftOO

8. 1/4" - 5/16" '6.3 .. - l.g _I. ADJUST lEltGlM Of ClEVIS IlOO AS REQUIW! willi SlllmlE 1M REY[1I5( TO ClTAIM THIS DIHEllS I 011.

9. 3/16" _ 1/4" (4.1 __ 6.3 _). WII" SHlIT1LE III fCI':IIARD. POSITION Ion to

151631

OBTAIN THIS DIMENSION.

Figure 2 - Mechanical Shuttle Control Installation

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Section 6212 TRANSAXLE REMOVAL AND INSTAllATION

J I Case

C. E. Dlv. 9-66015

.......... u.s......

A Ttlflnec<J Comoany

February 1976

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6212-2

TRANSAXLE REMOVAL 1.

Raise rear 'Wheels off the floor and block macbine In place with jack stands or other suitable support. Then remove rear wheels.

Disconnect drive shaft from shuttle output flange and remove from transaxle.

DiscoD.J1ect brake fluid line at bose to

transaxJ.e brake cylinders, 4.

Disconnect differential lock linkage at the transaxle.

Disconnect parking brake cable from cross shaft on top of transaxle. Remove cable housing clamp and place cable out of way.

Place transmission In NeutraL Remove rubber boot from gear shift lever. Then remove shift lever snap ring and remove lever and lever seat. Remove bydraulic tube clamp on the top rear of the transaxle.

If equipped with dual rear floodlights. remove wiring barness clall1l cap screws on the top right and left of the trans axle.

Remove tube clamp from right side of frame above the axle mounting pad. Clamp must be removed 60 tube can be moved to allow transaxle mounting bolt removal.

10. Place a floor (service) jack under the

front and rear of the transaxle. Be sure jack pads are in contact with transaxle. I L Remove the support straps at front of transaxle. 12. Remove nuts and washers from the four mounting bolts on eacb side and remove the bolts. 13. Lower rear of transaxle 1/4" to 1/2" (6 rom to 12 rom) and move trans axle to the rear until studs in front of transaxle clear the center crossmember. Then lower trans axle and pull from under macbine,

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6212-3

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1 oJi> ./

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6212-4

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Figure 2 - Parking Bra}te Control Installation

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6212-5

TRANSAXLE INSTALLATION 1.

Place transaxle on jacks and roll under machine.

Raise transaxle into place keeping the front slightly higher than the rear. Guide studs on front of transaxle into holes in

attach wiring harness clamps to tql right and left of transaxle. 7.

Attach parking brake cable to cross shaft on transaxle and secure clI:ble hOUSing to

bracket.

center crossmember. 3.

side and install hardened washers and nuts. Do not tighten nuts at this time. H a washer must be replaced. use washer specU1ed In the parts catalog. 4.

Connect differential lock linkage to transaxle.

Connect brake fiuld lines to brake bose. Bleed brakes as instructed in Section 7025.

Install the four mounting bolts on each

Install the front support straps and tighten all nuts and cap screws. Then torque nuts on rear mounting bolts to

250-300 foot-pounds (338-406 N m). The

-rear mounting bolt nuts must be retorqued after 50 bours of operation. 5.

Install tube clamp on right side of frame and tube clamp on top rear of transaxle.

If equipped with dual rear flood lights.

10. Install drive shaft aD transaxle input shaft and attach to sbuttle output shaft. Torque cap screws to 20-24 foot-pounds (27-32 N m).

11. Place shift lever seat on shift lever and install lever in transmission. Secure in place with snap ring and install rubber boot. 12. Install rear \\Iheels and torque wheel bolts to 115-130 foot-pount!s (155-176 N m).

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Section 6214 TRANSAXLE AND DIFFERENTIAL LOCK

JIClIse

ATenneooCompany

i!~

RIC 9-79231

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6214-3

GENERAL INFORMATION

CLEANING - Steam clean the complete eJlterior of the transmission case be10re any service work is performed. All metallic parts, ellcept bearings, should be cleaned in mineral spirits or by steam cleaning. Do not usa caustic soda solution for steam cleaning . All parts should be dried and lightly oiled after cleaning. Oil passages can be cleaned with compressed air. Bearings should be cleaned in mineral spirits and lightly oiled. INSPECTION - Inspection of aU parts should be made when disassembly is required . Any part that ,hows ellcessive wear or damage must be replaced. SmaU nicks or groov8S can be removed in most cases with a hone or crocus cloth. Thorough visual inspection for indications of wear, stress, pitting and the replacement of such parts as necessflry will eliminate costly and avoidable unit failure . GEARS - Inspect aU gears for wear and damage. Gears which ate wom. ridged or scored must be replaced . NOTE: If it is necessary to I'9place eitMr the bevel gear (differential ring gear) or pinion shaft. the bevel gear and pinion shaft must be replaced as a matched set.

BEARINGS - Check bearings for free smooth action. If bearings have a loose fit or rough action. replace the bearing. Always replace cup and cone as a set, never just one part of a bearing. Wash bearings with a good solvent and let air dry. DO NOT SPIN DRY . To facilitate assembly in many areas. bearings may be heated , This will eJlpand the bearing inner raCi!, eliminating the need of a hydraulic press when instalting bearings over shafts.

L"I.. ~

CAUTION Alw'ly.; wc.u asbestos gloves to prevent burnmq ynur hands whtÂˇn h,m dlmg heared p,uts

NEEDLE BEARINGS . Always remove any burrs in bore or edge 01 bore before preSSing in needle bearings. Lubricate inside and outside diameter of bearings witfl a lubricant before pressing into place. When pressing needle bearings into place, always use a bearing arbor. Place bearing on atbor with stamped end (end with numbers) against stepped shoulder of pressing arbor.

SHAFTS - Inspect all shafts 10r worn, pitted or broken splines. Also. check for damaged bearing and oil seal surfaces on shafts . OIL SEALS. "0 " RINGS AND GASKETS When installing any parts, always instaU new gaskets, oil seals and "0" rings. Lubricate rubbing surface of all lip type seals with a lubricant before installation.

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6214·2

TABLE OF CONTENTS GENERAL INFORMATION ........................................................................................................... 3 SPECIAL TOOLS ............. ............................. ........ .............. ............ .............................. .......... ..... 4 SPECIFICATIONS FOR TOOLS WHICH MUST BE MADE ........................................................... 5 SERVICING THE TRANSAXLE ASSEMBLY Final Drive Gear Removal ....................................... .................................................................. 6 Axle Housing Removal .............................................................................................................. 7 Axle Shaft Removal ........................................................ ....... ............................... .................. .. 8 Differential Side Gears and Center Wheel Removal .................................................................. 9 Mainlhaft Removal .............. .... ............................... ... ....................................................... ..... " Countershaft Removal ............. ... ............................................................................................ 15 Countarshaft Installation .... ..................................................................................................... '6 Mainshaft Installation ........ ............. ................ .. ............ ............. ........................................... . 21 Rebuilding Shifter Assembly Disassembly ......................................................................................................................... 30 Assembly ............. .... ............................................................................................................ 32 Installation ....... .................................... ................................................................................ 35 Rebuilding Differential Center Wheel and Side Gears Disassembly ......................................................................................................................... 37 480C L/B & 5BOC Forklift Center Wheel Build·Up ............................................................. 38 580C Loader/Backhoe Center Wheel Build-Up ..................................................................... 40 Rebuilding Differential Side Gearl ........................ .............................. ................................. 42 Setting Differential Pinion to Side Gear Backlash ................................................................... 43 Differential Center Wheel Installation ...................................................................................... 46 Setting Differential Bearing Preload ........................................................................................ 48 Adjusting Ring Gear to Pinion Gear Backlash ......................................................................... 49 Axle Shaft and Housing Installation ... ....... .............................................................................

SERVICING THE DIFFERENTIAL LOCK ASSEMBLY Remov,,1 and Disassembly ...................................... ................................................................ 58 Assembly and Installation .......................................... .................................................... ... ...... 59

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6214-4

SPECIAL TOOLS

G13503 PROTECnVE SLEEVE 013S~

OIL SEAL DRIVER

SPRING COMPRESSION TESTER

01&015 SEAL DRIVER

A44eo2 OIL SEAL DfUV£R

( G15~3

PROTECTIVE SLEEVE

DIAL INDICATOR

•

A14f1288 BEARING DRIVER

013&06 OIL SEAL DRIVE (2 1

INCH POUND AND FOOT POUND TORQUE WRENCH

0" TO 1 MICROMETER W

THERMO MOUNTER - MODEL ··C.. ELECTRONIC DESIONS. INC. 6164 N. 52ND STREET MILWAUKEE. WIS . 153218

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6214Â·5

SPECIFICATIONS FOR TOOLS WHICH MUST BE MADE

.-""" 3"~

01A.. ROD

TA~",ND ~I>

T;Y

/WW> 1_3 / " H 1.0. TUIING

IHIFT RA"- PILOT SLfEVl

NAINSHAFf SPACE!! TOOL

MODIFIED 'RAKE DISC

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6214-6

SERVICING THE TRANSAXLE ASSEMBLY Final Drive Gear and Axle Housing Removal

Clean the complete exterior of the trensaxle assembly before performing any service work.

Remove the cotter pin retaining final drive gear nut.

Remove the rear top Cover retaining bolts.

Remove final drive gear retaining nut and washe,.

STEP 3 IMPORTANT: Final

Drive Gear Removal â&#x20AC;˘ There are two methods by which the final drive gears can be removed from the tranlaxle case. ,. Complete removal of axle housings - follow Steps 6 thru 14. 2. Remollal of axle shaft from axle housing follow Steps 15 thru 19.

Remove the rear top cover.

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Axle Housing Removal

BefonI the finel drive geer een be removed from the tl'IIn..xle case, the exle housing must be perti.llly removed. Support the exle housing with a hoist.

Install two guide pins in transaxle case.

â&#x20AC;˘

Remove the rest of the exle housing bolts and pull housing from case. Remove the self adjusting brake retum spring.

Axle housing removed from transaxle case. Remove two ;!Ixle hauling bolts.

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62l4-8

Axle Shaft Removal

Remove the final drivt! gear.

Drive the axle shaft from the housing.

Suppon the other axle housing and remove axle housing and final drive gear following Steps 4 thru 12 . Drive ute from housing until the inner bea,ing cone is loose.

Both axle housings and final drive gears removed from transaxle case. Remove the final drive gear.

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6214·9

Mark the axle housing, bearing cup and cone before removal for correct aide plecemenl of ~rt8 during assembly. NOTE: If etmer b. .,· Ing cup or cone are rep"~ , atways replace both helves ot the bearing.

Remove the cotte.- pin Ncuring the other final drive gear nut and repeat Steps 16 thru 18 for final drive gear removal .

Differential Side Gears and Center Wheel Removal STEP 20

Remove brake return spring and bolu Hcur· Ing brake housing .

S ... ke housing removed from transaxla case.

Remove the breke housing.

Remove the brake drum assembty.

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6214-10

Remove the screws securing the differential bearing carrier.

Remove the differential bearing camet" eni:! shim,.

Remove the differential side gear assembly.

Remove the side gear shims, mark or tag shims for relocation during asaembty.

STEP

Differential bearing carrier removed .

r "

2 ~9;....

Remove the L.H. brake housing and side gear following Steps 20 thru 28.

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6214:111~

l.H. brake housing and differential side '§e'er': i removed nom transaxle case.

Differential removed ' from transaxle --case.

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Removal

Remove the bolts securing front top cover.

Remove front top cover and shifter assembly.

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6214·12

Remove the mainsheft yoke.

Remove the transaxle rear cover.

o Remove the transexle front cover.

IMPORTANT::Rfltain the shim peck

Inmllation procedure.

:i"

Before the lNIinshatt-and gears-can be removed. the front bearing cup and cone must be un...ted, UnHating of bearing Wil! i llow acc;eu to tha captive anap ring. This snap ring mud be perttalJy removed before the mainshatt can be removed. "

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PIa'ti-i two 'large .. c 路路 clamps on 4th .geerJ."1Inct,,路路 draw gear evenly until it makes contact .witt,""a. transmission case. NOrE: ' As gear is drawn towards ca.58 the mainshah will also move.

Move snap. ring ,Aown shaft until i1 ~JW;s C0R-:.i~ tact with 1 s1! and-.2n,d sliding gear.. .(1 , .....

Wid, a

soft headed. hammer, drive mainshaft into case.

Move the captivating washer towards 3rd g8ar uncovering snap ring _

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6214-14

Placa a large! rOd through the rear opening in the case. Drive the mainshaft forward out ot the 'rear bearing cone, NOTE: Use Âˇextreme care when driving shaft to prevent damaging rea bearing .

Pull mainshaft from gears.

case.

removing

shaft

( ; Mainshaft removed from transal(le case. Drive mainshaft until it has el(ited from case inches.

...

,', ; , .

Remove spacer tool and prybars .

â&#x20AC;˘

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6214-15 :;<

Countershaft Removal

,--.

STEP 51 Before disassembling the countershaft assembly. the -clearance between 2nd and 3rd gear hubs must be measured and recorded for use when the countershaft is reassembled. NOTE: Any new partl s that are installed must have their hub thickness measured and compared against the hub thickness of replaced pert/s. This will determine spacer thicknesa required to maintain necessary clearance between gears during assembly.

With a soft headed hammer, drive pinion shaft into case.

To measure clearance, do not merely tilt the gears on the shaft splines. use two screwdrivers to spread gears apart and cheek clearance with a feeler gauge.

.....-

Remove adjusting nut and front bearing cone.

â&#x20AC;˘ Lock up countershaft gears with a prevent rotation and loosen the shaft nut.

Pull shaft rellrward into ease, removing gears.

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6214-16

.-,~

>-.

o •

Countershaft

remove d from trans-

axle case. _

Countershaft Installation

•

...?-

•

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6214-17

Install pinion shaft resr bearing cup and snap ring into ease until the $!lap ring is firmly

seated against bore s houlder.

Heat pinion shaft rear bearing cone on a bearing heater.

CAUTION Always weiH asbestos

,,/(Jve~

lapFel/en, burning YOIIT hands when han dlmg heated parts

Install front bearing cup snap ring in case

groove.

Place heated bearing cona on pinion shaft. NOTE: Bearing must make contact with pinion gear end of shi!lft.

Install front bearing cup {small 1.0 . inward}

until cup seats against the snap ring. Install pinion shaft in case through rear opening.

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6214路18

Install 1st speed gear on pinion shaft with gear hub forward.

Install 2nd speed gear on pinion shaft with oil slinger gear towards spacer.

a .. ~

Install 路narrow gear spacer.

Instat! 3rd speed gear on pinion路 shaft. "

Install oil slinger gear "on 2nd speed geBr; hub . . -::.~.

Instat! Wide ,gear spacer -on 路 ~i!,iC?n shaft. ~,

','

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6214Âˇ19

Install 4th ,peed gear on pinion wft with gear hub fofWfIrd .

After the correct size sPlIcer has been determined, inmll spacer on pinion shaft.

MMsure gur .. lective sPlIcer thickness and prov~ .001" to .ooe" clM,..nce between gMrs, Me Steps 51 and 62. NOTE: Selec ti .... spacers are furnished in increments of .006 ", fanging m size from .164" to .244". Do not use shim stadt.

Hut the front beering cone on a bearing heat' eT lind install heated bellring on pinion shaft.

Remember: A. W~ the total thickness of new parts islHs Ihlln the thickness of rep~ced parU,.Jmt the differenCfl in thIckness to clearence figure obtained in Step 62. If the ~m of the .. two figures exceeds .ooe". a thicker spacer must be used.

STEP 74

select comet spacer which will

CAUTION to 1'''

{/I"",

'It

"i., 'V' w,'." ."',,., ,"

I r /"",,,,,,, yo", 11./1"" ... ,

1/""

I/{" , , ,,, II'

I"":'

8. When the total thicknti .. of new paru Is Af!!ter than the th/clut... of replaced p.m, subtreet the difference in thickness from c"',..nce figure obtained in Step 52. If the result is ~ than .001 a thinnef apecer must be used. H ,

Install pinion wft adjul'ting nut and tighten nut until bearing endpiay is removed.

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Preload counterahaft bearings, such tlMt a torque of 4 to 12 inch pounds above no load rolling torque is required to tum countershaft ....mbIV·

Chetek the c ......nctl batwMn 2nd .nd 3rd gur hubs with a feeler gauge .nd g"'s spre.d apart. C ......nce mull1 be .001" to .008". If cIee...nce is incorrect. a different ab:e spacer mull1 be used. Remove re.r be.ring cone and, spae8f. repeat St~ 73 thN 78 until prOf*' c ......nce itI obUlned.

Tap both .nda of the pinion sh.ft to help ...t bHring, then rechedl; the bearing rolling torque, Step 71. Peen the thin section of adJuatlng nut Into ahaftslots to lock nut in place .

.\+

•

" •

•

...

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6214·21

Mainshaft Installation

1ST AND 2N O

1 0' NG GEA, REAR BEARING CONE

./ //_,

/'" /'" '" ,,/

,= .

•

3RO &. 4TH .............. SyNCHRONiZER......

~ (W.

't'/iJ a

C /

." , .. W' OE

GEA. 'VSH'NG

FRONT BEARING CUP /

/@fOd:

THRUST COLLAR 196 ·· W10E

lOONG G . . .

'...... ............

THRUST WASHER

/"'" /

SNA P RING

,"0

GEA R BUSHING ......

0ov/ / Vi

...........)

THRUST WASHER /'" ....... 125" wIDe ...... / '

FRO NT BE ARING CONE.........

'"COT

co.....

/'"

~/CO'" ,FRONT SEAL

SH IM · .005 - .. 007·· &. .035 -

@~ \

INPUT YOKe

SYNCHRONIZER ASSEMBLY

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621.-22

Install rear mainshaft bearing cup snap ring in

case groove.

ApplV #2 Permlltex to the outside suriace of the reaf bearing oil cup.

STEP SO

t ': ;;J>

c Install rear bearing cup (small 1.0. rearwardl

Align oiling cup notches with case openings and

into case until cup Hats against the map ring.

press cup into case until it ia flullh with caM.

STEP S1

STEP

Rear bearing cup installed in transaxla case.

Heat front bearing cone and install on malnshaft so that it extends 1/16" passed step on

shaft end.

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STEP

Start malnlhaft through front opening in caM and install thru*, collar 1.196" wldel on main-

Inatal1 thrust wa.her (.12S" widel on mainshaft .

.... It.

Install gllar bushing on mainshaft.

Install the th,.. ."jfter platH in synchronizer Inu-II 04th QUr Iflat .ide towards case front) on mamahaft over bultllng.

skHt\le groove..

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62140"

STEP 94

Retain the ",ifter plate. in place with spring.

Install synchronizer assembly on mainshatt. IMPORTANT: Short sleeve hub side of Iynchronizer must face forward. see Step 94.

l Tum the synchronizer hub and sleeve over and

install-the other shifter plate spring . Install thrust washer (.i26" wide) on mainshaft.

MealnJf'& synchroniur , leave hub length. noting which side h.. short hub length and place blocking rings on synchronizer hUb.

Install gear bushing on mainahaft.

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621"'Âˇ25

In.tall , st and 2nd sliding gear (small gear

Install 3rd gear (tapered h .... b towards synchronÂˇ izer) on mainshaft over the gear bushing.

rearward) on mainshaft.

Inlwll captivating wa.her (flat 'ide towards

Place rea, bearing cone in be.ring cup.

3rd gear) on mainshaft .

Install gear retaining snap ring on main.haft. but do not place snap ring in shaft groove at this time.

Position mainshaft so that it is aligned with and just started into rear bearing cone.

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6214-26

With a soft headed hammer drive mainshaft into rear bearing cone.

Caf$ft:Jlly drive bearing cup into housing bore until it is flush with housing.

c Pull gear cluster as far forward as possible and install snap ring in shaft groove.

Place front bearing cup in housing bore.

Place a new front cover gasket on housin.g.

Press pilot bottoms.

collar

front

cover

until

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6214·27

, In&1811 front cover on houling.

Torque front cover 1 / 2" mounting nuu 80 to 98 ft. lb •. and 3 / S " mo'unting nuts 36 to 42 tt. I...

Place. wadge between 4th gear and houling. S.at fTont bel!ring cone. removing all and play between ;Mrs, NOTE: End play will be removed "when captive snap ring il tight.

STEP 1;3

......T , _.J

"'.ce main front bearing driver A148286 on mains...ft .

R.mow

tt.

fTont cover and re-install the old

.... Im .-ck. ret.lned hom Step 37 during disauembty. minUi aome shims to ...ure an end play rnding •

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6214-28

Reinstall nont cover and torque 1 / 2" mounting nuts 80 to 96 ft. Ibs. and the 3 / S" mounting nuts 35 to 42 ft. Ibs.

Remow front cover and add shims to achieve .000" to .001" end play to .001 preload. Shims are available in .OOS", .007" and .035" .ize â&#x20AC;˘ . ReÂˇinstall front cover and torque nuts a. spec_ ified in Step 114.

(

Tap the back end of the main shaft with a soft headed hammftr and rotate the shaft severel turns while tapping shaft.

Tap the back end of the main shaft with a soft lteaded hammer and turn shaft at the . .m. time a' least three turns. Place a dial indicator at the back of the shaft with indicator probe on thai face of the 1Mr bearing cone 8. shown. Move shaft back and forth. while reading Indteatot", which will da,ermine the amount of shim stock that must be added to provide correct .001" shaft end play or close a. possible to .001" play.

Recheck for shaft end play with a dial indicator as shown in Step "6. End play must be _000" to _001" to .00'" preload_ If not, add or .ubtract shims, see Step 116, to obtain correct end play and preload.

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6214·29

Oil shaft yoke and carefully install over shaft and into ••• 1. NOTE: Voke must be hand in-

(. .(it.

stalled, DO NOT drive onto shaft with hammer.

USED , - - SHAFT YOO" I

onow ...1 {lip inward, ... Inset. in housing cover, Apply an inch pound torque wrench and an .cIapt., to front and of sh.tt and check the rolling torque. The rolling torque must not exceed 5 inch pounds for correct bearing preload. including seal drag. It mora than 6 inch pounds. shim or shims may have to be removed. NOTE: A make·up adapter may be made from II used yoke, see inset, by bnlzing II nut to the used yoke.

Main,haft assembly installed in tran •• xle housing .

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6214·30

Rebuilding Shifter Assembly

KNoa--- - a

JAM NUT R"AlN,NG SCR'"

DUST COVER _ _ •

....-

__\ - / ' /

x~ ~~"'~~COVER

SNAP R I N G - - - . . ; )

I I I I

HAND lEVER--_ _ ~!"'.i

I /

'-/

...- ...-

..-

/ INTERLOCK PLUG

• 3RD AND 4TH

~ '''RN02NO~~ ~ _ _.

SPRING

__ -0 .

OElEN' BAll-

SHIFTER roRK

SHIFTER

RAil

SPiRDl PIN /'

3RD AND 4TH SHIFTER FORK

Place the sh ifter auembly on a suitable woril surface.

Remove rubber bool and seal retaining snap ring.

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6214-31

â&#x20AC;˘

Remove gear shift hand lev....

Drive rail through 1 st lind 2nd fork end remove fork.

( Tum shifter cover over on its top.

Cover the openings in shift cover when removing rails to prevent injury from the flyÂˇ ing detent balls.

STEP 128 Repeat the .. me procedure removing 3rd and 4th shifter fork and rail.

Remove the roll pins retaining fork, to shitt-

er rens.

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62}4·32

•

Assembly STEP 129

STEP 1

c-- -

•

• Install steel detent ball in cover on top of spring.

Inspect the detent springs. springs must meet the following specifications: Freel.ngth ........................................ Optional 0.0.. ...•...•....•............•..•.... Work in .390" bore

Compressto.812" ...................... 28to461bs. Wire dia. . ....••...............................•........072"

STEP 130

Install pilot afeeve to compress detent spring and ball. Refer to Page 6 for sleeve specifi-

cations.

InstaU detent spring in 1st and 2nd housing bore .

.....

•

Install 1st and 2nd shift l1Iil (rell with 6/8"

lands between detent slots) part way into cover.

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6214-33

Install 1st and 2nd shift fork (small fork) on shift rail.

Install spring and ball for 3rd and 4th shift rail.

STEP

, Using piklt ....ve. Step 132. Instllil 3rd and Cth shift rail and fork. 'Nl~R''')('' ....UG

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6214-34

Inatall fork retaining spirol roll pin.

Install shift lever in cover top opening. Make sure levar engagas shift fork,.

Shift rails and forks installed in shift cover.

Install ga.r shift lever seat.

1ST ANO 2ND

'H'"'' '""~.I..._j/L..J., â&#x20AC;˘ 3RD AND 4TH

SHIFTER FORI(

Install lever seat retaining snap rmg.

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InstaU shift leve r rubber dust cover.

Instlln a new s hift cover gasket.

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6214-36

Rebuilding Differential Center Wheel and Side Gears CUP PLUG

L.H . SIDE GE AR

THRUST SHIM - .010"

CROSS SHAFT

580C LOADER / BACKHOE BEARING CONE

~ ~

,,/ ,/ -

//'

.........

/ B O l T - 3 / 8 X 7 / 8" GR . 8

~ ()\tI- - - H ARD ENE D WA SHE R ,,/ ,,/

TAPER DOWEL

,,/

,,/ .........

......

,_/

,,/

CENTE R WHEEL

,,/

PINION GEAR GEAR PIN GROOVE PIN

~\.Y"" ~

R .H. SID E GEAR

480C LOADER / BACKHOE

BUSH ING

BE ARING CONE ----....~

OIL SE AL

L.H . SIDE GEAR

BE ARING CONE

~ .

THRUST WASHER .08"9" TO ." 9"

RING GE AR AN D CENTER WH EEL ASS EMBLY

580C FORKLIFT

8US\ G.~~.4

fff~ \

OIL SEAL

~_ _

.::? ---- GEAR

BEARING CON E GROOVE PIN - - -

PI NION GEAR

PINIO N 'GEAR

~ _ _ GEAR PIN PIN

.::?- - - GROOVE

6214-37

Disassembly

Remove the pinion gelr retainer groove pin •.

Place the center wh..t In • hydnllliio preu and

.-ft

croa out ot cent.- wh.... IMPOR· TANT: Pna on shaft end w l o apl"'. since .pI..... tllpered in one dl,.o1Ion only.

_ft

preM

Loa.n the pinion pin •. Cross shaft removed from center wheel.

NOTE: On SBOC Loader/ Backhoe model., the ring geer can be removed from thtt cente, wheel for replacement of elth., part. If the ring gear and cen ___ wt..1 .,. dlaauembled, always re· place the retlilnlng bolta. On 480C Loaderl BackhM or 580C Fortuft models the ring gMI

and centet- wt-a mUlit be Nplaoed Oil .n _ ..nbty. since theM fMrta .,. ,iveted togeu..r.

V-.....

Remove pinion pin • •nd h.lpeGt gear bo .... 19r out-ot-round and rough .pots. Replace gMrs if worn. damaged or pitted.

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6214-38

480C LOADER/BACKHOE & 680C FORKLIFT CENTER WHEEL BUILD-UP STEP '56

c Place the ring gear and center wheel ....mbly in a hydreuUc press. a. shown_ Start 'the ero.. shaft into the center wheel. NOTE: Shaft spline. .re tapered in one direction onlv, 80 start .ptined end of shaft into center wheel.

Install pinion gears and pins. NOTE: Make sure pin retaining hole aligns with center wheel hole.

Install plntOn retaining groove pins untilthay are f1u.h with center wheel. Press ero" shaft into eenterwheel until smooth area between splines is visible in pinion gear mounting holes.

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4BOC loader/ Backhoe center wheel. ring gear. cross shaft and pinions assembled.

5BOC Forklift centerwheel. ring gear. cross shaft and pinions assembled.

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6214-40

6aoc LOADER / BACKHOE CENTER WHEEL BUILD-UP

Apply loctite #271 (C••• No. 817423) to the ring gear tapped threads. 3

'b,...._-O--...:O 0" 10

BOLT TORQUE PATTERN

0' ......_.....-'0 • 10

°•

Place the ring gear on the center wheel. NOTE: If the ring gear's being replaced, the pinion shaft must slao be replaced 5ince these parts are • matched set.

IMPORTANT: To insuN adequate loctite reo tention and even mating of ring gear to cente,~ the following torque sequence must be followed. 1 _Tighten bott. 1 and 2 simultaneously by hand until tlnger tight . than tighten bolta: 1 and 2 alternately 1/ 2 tum at a time un· til 30 ft . Ibs, Is ruched. 2 . Ttghten the remaining bolts (3 thru 12) to 30 ft. lb.. in thtI numerical sequence

""'_.

3 . T'Uhten bott. 1 thfU 12 to 40 ft. Ibs. in the

numerical Mquene8 shown .

Inmll tapered ....ves. hardened washers and new retaining bolu;.

4 . Then bacM-off each bott (one at a time) until 100.. in numerical sequence shown andretorque bolt 50 to 65 ft . Ibs. NOTE: each bolt must be backed off and retorquod before proceeding to the next on8.

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Place ring gN' end center wheel ..sembly in

Instell plmon rotaining

• hyd .... ulic pre••, as shown. 5t11rt the croll shaft into the center wheel. NOTE: Shaft aplin •• .... tap.erod in on. di ..ction only. SO start

are flulh with anter

9roo~

pin. until they

w~1.

Iplined end of 'haft into center wheel.

Center wheel, ring gear. crop ,haft and pinions assemblied .

p,... cross ...aft into center wheel until

SIn()(lth

am between spline. is ""sibIe In pinion gar mounting hal••.

NOTE: The S80C loec*/ Backhoe aide gu,.. kaYe an Identification groove cut In ttM ctontef of the 'PUr gae,. Do not UN theN

Install pjnion gN', end pin•. NOTE: Make are

stet.

g .....

on .e8OC or I580C Fortdlfts, ,inee tt..y will not property rna. with tt.. filVl' drive gun,

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621.-42

Apply #1 Pennatell to the 0 .0. of a new cup plug.

Press bushing in until the out.r edge is even with the shoulder or .tep in the side g •• r.

u Drive cup plug into L.H. sid. gear until it bottoms in gear bor•.

STEP 170

Place new bushing in R.H. side gear.

Using A44S02 oil sea' driver, press new se.1 (lip inward) ntil It bottoms on gear shoulder.

-"'"

STEP 173

Heat bearings and insull on R.H. and L.H , side gears until they bottom on the spur gear.

CAUTION A/Nav' WI

to 1''' ',/"n/ bUff""'/ yo "' rift"" ,,,. ,It'd pdf!'

."In Has glow"

h,lIIrI~ whelJ h""

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6214-43

Setting Differential Pinion to Side Gear Backlash

Tum L.H. lide gear 0118' and place a nominal thickn ••• thrust washer in side gear.

Hold side ga.r in place and rotate pinton gear

STEP 176

ter wheel and check backlash at various sections of side gears.

Place

dial indicator on pinion g_r tooth.

back and forth. checking backlash. Rotate cen-

IMPORTANT; Sacklashmust be .005" minimum at the tightest pinion gea, and must not exceed .015" at the loo••st pinion gear.

Place center wheel assembly in side g_r.

STEP 176 " -_

•• A .006" change in thrust washer thickneh will change backl.sh approximately .0036", NOTE: Thrust wash.r. are available in size. from .089" to .119" and st&81 shims are available in .010" size.

Check pinion gears to Inaure there '- some backlli.... present. NOTE: Instilil • !hickM thruat w•• her if no backlash is pre..nt. Thrust washer thicknesses .089" to ." 9",

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6214-44

STEP 179

Place a nominal thickne.. thrust wa.her on cross shaft. NOTE: L.H. lide gear. thrust washer and shiml mUlt be removed.

Place a dielindleator on pinion gear tooth. Hold side gear in place and rotate pinion gear back and forth. checking backlash. Rotate side gear and check backlash at various ••ctions of

side ga.r.

18•.::, 0 ......_

IMPORTANT: Backlash mUlt ba .005" minimum ,at the tightest pinion gear and mUlt not exceed .016" at the loosest pinion gnf.

c Install R . H. Side gaa( and check pinions to insure there il bactl:lash present.

•

A .006" change in thnr.t wa.her thickness will change backlash approximately .0035", NOTE: Mark thrust washer and shims ~f required for location during ...."..bly.

•

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6214-45

S80e l.OADER / BACKHOE

â&#x20AC;¢

()

480C LOADER / BACKHOE 580C FORKLIFT

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621446

Differential Center Wheel Installation

~---Oll

SEAL

CARRIER SHIM • •OO3 ootl" • •010" H

••

• m",NGCU~ ./

(

" ,,

-_/ " " "

./ ./

l.H.

)

.089- TO _\

THRUST WASHER·

,/ ,/

-- , , , , /'

THRUST SHIM· .010"

THRUST SH'M - . 0 \

."..-- .......

./ /"

/,,"'"

IlEARING CUP

.............

"\.......)

"TMRUST WASHER •

.OS9" TO .119

././

""-__ ,,:,,:s:,,,\ ", 1

~, ~

(j" : ~)~:~~.ow

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SEARING CARRIER

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6214-47

....

Install R.H. thrust _ ..... , and Itllm•• If , . quired.... Stepi 179 thru 182. NOTE: If steel Itliml .re UNd. they must be In.tallttd flm nIIJrt to cen~ wh..t thrust luri-ce. .

In.tatl CM'Iter wheel ....mbly in tranu.1e hou.Ing.

Inltlil R.H. lkie gfNIr over crOll shaft.

Note locetion of center wheel to pinion Ihaft.

C.I

Re ....stall original shim pack or a nominal amount of shims. NOTE: Make lure small center t.ole • down to allow for oil d .... inage.

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6214-48

Setting Differential Bearing Preload STEP 188....._

STIU;>9,,:'--o~-

Install bearing cups in side gear bearing carÂˇ riers until they bottom.

With a torque wrench on special tool. measure the turning torque required to tum one differential side gear with counter,haft pinion gear locked against rotation. Turning torque must be 3 to 8 ft. Ibs. to property preload load differential bearings.

u Install both bearing carriers and torque retaining bolts and nuts 70 to 90 ft. Ibs. NOTE: When torquing up carrier, make sure backlash e.ist between ring gear and pinion gear. Add or delete shims as necessary between bearing carrier and housing to obtain proper bearing preload.

Install special tool. which can be made from a brake disc .... Page 5.

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621449

Adjusting Ring Gear to Pinion Gear Backlash STEP 193 PiNION

OEAR--~

RING GEAR--{1

ANen the

on.

<J>,~- AUON MARKS

merked tooth on pinion g_' to

the two rMlrked teeth on ring gur, Th_

ttl,.. teeth tulve beltn mark" to incm:.. the position of minimum beckle'" .nd, e. .uch, must In~"""h when setting becldeah.

Remove bearing carrier end In.tall 016603 protective sleew over .'de gee, spline• . NOTE: Co.t outside of ......... with Ce .. FDl.

o Pfece • diel Indicator on ring o. . r tooth. With pinion IMT locked Itg.wm rotation. chedc gu, beetd. .". Becltle'" must be .006" to . OOS".

Usi"9 G16011 driv.r. pr... new .. el in beer· ing cerrler. NOTE: Coat the Inslde of teal with CeM FOL

Move bearing cerrier mims fTom right to left side beckJuh end from left to right side backlash . NOTE: Do not change number of .hims since totel shim thtckne.. is required to maintain diffM.nde! buring pt"eload .

Instell new " 0 " ring in baring CIIrrier groove.

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6214-50

Slide bearing carrier over protectiva sleeve.

Apply #2 Pennatex to the threads of the bolt which is installed in the straight through tapped hole. Instal.1 blake housing and torque retaining bolts and nuts 80 to 96 ft. Ibs.

NOTE; If brake I8rvice is required, refer to Section 7122 for Servicing the Self Adjusting Differential Brakes.

c Install carrier retaIning screw and pull sleeve out through the carrier assembly.

Install the left hand bearing cartier l8al and "0" ring following Steps 196 thru 200. Install L.H. brake disc and drum assembly following Steps 201 and 202.

â&#x20AC;˘

,. Install brake drum and disc assembly on slde gear_ NOTE; Brake disc (spUned piece) must be . in~Ue ~ against bearing carrier.

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6214Â·51

t ,"

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•

62U-52

Axle Sha ft a nd Housing Installation FINAL DRIVE

COTTER PIN

~ ~SHAFTNUT

~ASHER

•

./ II .-

"'\

\, ,

/ /'

;-' ......... ,

OUTER BE""'N

/ ' / ' /O;;":BEAR'NO

~v)

GCUP' .........

CON'~~

GR'ASE 'OTTONO / ' / ' .......

1/8" X 415' /'"

'- / ...., .. Oil SEAL OU._

(

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â&#x20AC;˘ 6214Âˇ53

STEP 207

Stand axle shaft on end and place protective lleeve G15043 on IXI. shift.

Preu new oil seal (lip up) over sleeve and onto a~le shaft . NOTE: COlt seal lip with #2 lithium gun grease.

Install two G1360S oil seal driver. under the

oil seal.

Use tubber band. to hold Utll dri\lers in position.

STEP 206

Remove protecti .... slee\lit and heat bearing cone on a bearing heater. Install heated bearing on we shih . NOTE: Bearing must contact .haft shoulder.

Install a"le housing inn8f bearing cup until h: is firmlv seated against housing shoulder.

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6214-54

Place inner oil Mal in ule housing.

Inllt.lI axle housing outer bearing cup until it i. firmly seated against housing .houlder.

Drive oil seal into position using G13504 driver. Axle housing ready for installation on transaxle ca ...

STEP 215

Inst.Il a new "0" ring in axle housing groove end lubricate "0" ring with SAE 90EP oil.

In.tall two pilot stud. In tr.nsaxle ea...

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6214-55

Place 1he axle hou.ing on thll pilot nlds and slid. housing into place, ~no ca,.ful not to damage "0" ring.

Instllll final drive g.ar in uansaxle c .... NOTE: Gear .. Itamped "Nut Sid. " for proper posittoning.

ApplV #2 P.rmatex to the threads of the bott which is Instelled in the streight through housing tapped hole.

Insull axl. shaft in ole housing. NOTE: Aft« completing Step 223. remove ••al drive,... tf ... 1 is not flu.tl with housing. usa • .crewdri~r to wort.: _I there," of the w~ into housing until flush .

In.tell uI. mounting bolts. Torque Gr. 6 bolts , 50 to 180 ft . Ibs. and Gr. 8 bolts 220 to 264 ft . lb • .

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6214-56

Position final drive gear on axle shaft and inmil flat washer and retainer nut.

TIghten nut to seat bearing cups and cones. Rotate axle shaft a few turns, then retighten nut until it is snug. After the nut has been "Sflugged up", tighten the nut one additional notch (1 / 6 tum) and install cotter pin.

lnatall a new top cover g ...ket.

Install top cover and torque retainer bolts 35 to 42 ft. lb â&#x20AC;˘.

Fill the trenuxle housing with 20 quarts of new Case FDl oil and install the housing dipstick. Repeat Steps 213 thru 223 to instaU the other axle houling end shaft.

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6214Â·57

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6214-58

SERVICING THE DIFFERENTIAL LOCK ASSEMBLY Removal and Disassembly

,_., .

'(I f

Remove the bolts retaining differential lock cover to R.H. brake housing.

Remove the roll pin securing actuating lever to shaft.

STEP 229

Remove differential lock assemblv from brake housing.

Remove the shaft from the differential cover.

Remove roll pin from shaft.

Remove the engaging collar and lever fingers.

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6214· 59

Remove pedal

~ver

from shaft.

Assembly and Installation COUAR

~:::R C£VS\

INNER SPRING

~~~~" ~R ~ V ) j / ""NO R.,.,""

DtR'ERENTlAL LOCK COVER

~CD\\a9." SHAff COVell IWIHING

\ OUTER SPRING

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621«0

Install pedal lever return spring on shaft.

Inmll a new lever retaining roll pin.

Outer lever spring specifications: Length ............................................. 2.06" 1.0 .................................................... 66'" Wire di.a ............................................ 192" No. of coils ............................................ 6 Free angle between wire ends ........... 138D Torque with wire ends at 112· angle .................. 42 to 95 in. lb•.

u ~

;AJ ,

Place new bushing in cover opening.

Install the actuating taver on shaft.

Press bushing into cover until rt is flush with outside edge.

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62''-'1

SUitt .... " In(o cover Ind In.usll ~rlng on Iha". NOTE: Coat all parts with Antl-Saiu Compourtd fC". No. M20466 or M20466) bofON inltall In differential cover.

Inflall lever tinge,.. in actuating lever.

...

1..: . . '

Innar lewr spring specifications: Length ............. ............ .. ..... .......... .. .. 1.81 " 1.0 ......................................... .... .......708" Wi... die ........................................ .... 1315" No. of coilS ..................................... 5 __1 / 2 Free angle between wire ends ........ ... .. 81Â°

Torqu. with

Iho~ WiN

and

d 24Â° anSlI4l .................... 18 to 28 in, fbi.

InltaR collar In difffh'8ntial cover making lure col .... engagu lewr fingera .

Inltall .ctuating lever on Ihaft and secure in paace with new roll pin.

Om.r.nda' anembly completed Ind _dy fir ",stalWlon on R .H. braka houling .

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6214-62 STEP 248

I =~ROU."N R:J::!. /

SHAFT

~t<._ -,

G::I

• PRONG

CEVER/ /~@ OUTER SPRING

/ RETAINER

Inltal1 differential lock on R.H. brake hauling, engaging actuating col1.r splines with differential CfO . . shaft Iplines. LEVER

I HORIZONTAL

. 23'

RETAINER

Install cover retaining bolu and torque batt. 17 to 21 ft. Ibs.

With the outer spring prong in No. 1 hole of spring retainer, mow lever upward. to ..... move all lfack fTom levitr. The lever Ihoukt bll Into tho below horizontlll 6° to 230 tolerance that the dfff. lock requi..... If not. the retainer i. to be ,..-noved ....d turned 1800 .0 holes 2 and 3 are at the top. The .pring is then to be us.d with holes 2 or ·3 to achieve the 6 0 to 230 below horizontal tolerance.

Differential )oct( auembly installed on R.H. tn•• hou.ing.

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Section 6222 .... r

• ' ot:

DRIVE SHAFT

•

"-, .-.....,."""'~

J I Case

."1-

••

C, E. Div. 9-66015

ATenneco Com~"",

_.-

February 1976

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6022-2

TORQUE AU CAl SCIID/S TO

2D-Z' FOOT-POUMOS (Z1.12 N. ) UNIVERSAL JDIKTS ARE SERVICED AS AN ASSEMBLY ONLY

POWER SHUTTLE

MECHANICAL SHUTIlE

1 ~ 1 '11

F igure 1 - Drive Shafts

â&#x20AC;¢ -

Ii'

.......

II!.

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•

_iV~

'niT

•

J "

•

..-.

Section

)" • •

6229 •

WHEELS AND TIRES

JICase A T,nntoco ComOAtly

C. E. DIv. 9-66015 February 1976

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6229-2

Front Tire Pressure

Wheel Boh Torque

7.50 x 16, 10 PR . , . . . . . . . . . .

Front and rear ..•. ,. 115-130 foot-pounds (155-176 N m)

56 psi (385 kPa) llL x 16, 10 PR . . • . . . . . . . .. 48 psi (330 kPa)

Rear Tire Pressure 14.9 x 24, 6 PR, Rl &R3 . . . . , , ,. 18 psi (125 kPa) 14,9 x 24. 6 PR, R4 . . . • . . , . . . . . 20 psI (140 kPa) 14.9 x 24, 8 PRo R4 . . . . . . . . . . . . 24 psi (165 kPa) 16.9 x 24, 6 PR, R3 &R4 • . . . . . . • 18 psi (125 kPa) 16.9 x 24, 6 PR, R4 . . . . . . . . . . . . 24 psI (165 kPa) 17.5L x 24, 6 PR, R4 . . . . . . . . . . . 16 psI (110 kPa) 17.5L x 24, 8 PR, R4 . . . , .•••..• 22 psi (150 kPa)

NOTal After a wheel has been removed and installed, check bolt torque every two hours untU torque stahUlzes.

Installing Wheels 1.

Do not use an iIr.pact wrench toturnbolts

into place. Damage to the wheel may result. Turn bolts into place byhand or with a hand wrench. 2.

Center bolt holes in Wheel and hub or axle fairly close before tightening bolts.

Alternately torque bolts to specification.

•

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Section 6406 CLUTCH AND

PRESSURE PLATE

JICase

C. E. Dlv, 9-66015

A Tenneco Company

February 1976

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6406-2

CLUTCH AND PRESSURE PLATE

Special Tool The special tool shown in Figure 1. or a shuttle input shaft. must be available to align the clutch plate whenever the clutch plate and pressure plate are being installed. Order part number A37956 from SPS in the usual manner.

10. Move the shuttle/flywbeelhousingaasembty to the rear and lower it to the floor.

11. Remove the pressure plate mounting cap screws and remove the pressure plate and olutch plate.

Installation 1.

Before installing the clutch and pressure plate. cbeck the pilot bearing in the flywheel for free rotation. Replace as required.

Use the special tool shown in Figure 1 or a shuttle input sbaft to position the clutch disc. Then install the pressure plate and secure in placewithcapscrews and lock ,washers.

Figure 1 - Special Tool

Removal Disoonnect drive shaft from shuttle output flange and remove drive shaft.

Disconnect clutch linkage from arm on left side of flywheel housing.

Remove cover at front of flywheel housing.

5. "Place hardened washer on bolts 8Jld in-

Disconnect connect control linkage at rear of sl:n.ittle.

stall from engine side. Install remaining hardened waSher and nuts and tighten all nuts.

Disconnect wiring from neutral start switch on left side of shuttle.

6. 7.

Raise Shuttle/flywheel housing assembly move into place against engine.

and

Install lock washers and nuts on studs at top of flywheel housing bJt do not tighten.

Install the rear engine mounting bolts.

Connect control linkage to rear of shuttle.

Connect wiring to neutral start switch.

Connect olutch linkage to arm on left side of flywheel housing.

Support the eogfne with a jack under the rear of the oil pan.

Remove' the rear engine mounting bolts.

Place a transmission jack Wlder the shuttle/flywheel housing assembly.

Remove the engine to flywheel housing nuts. washers and bolts. The fiat waShers are hardened. If a washer is replaced. use part specified in parts cata-

log.

10. Install drive shaft and torque oap screws to 20-24 foot-pounds (27-32 N m). 11. Install oover on front of flywheel housing. 12. Adjust clutchpeda:l free travel, Figure2.

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6406- 3

~:i!! LENGTH 0'

ClI.JTC~. ~~DlAL'l l2: ~~."~:OOIUO HoE TM~EL. - - 51 -

)

....... insWlation Figure 2 - Clutch Pedal and Lin!. ~~

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PRESSURE PLATE (42.799 mm) at 95-105 pounds (43.0947.62 kg).

Di..... mbly 1. 2.

Turn look nuts up against shoulder on the lever adjusting screws. Apply light pressure against the spring plate until the links are loose and re-

Assembly 1.

Install cUps on adjusting screws 'if these parts were separated or new parts are being installed. Be sure lock nut is OD adjustiDg screw.

Install clips on levers and place frame on tx:lp of pressure plate. Be sure washers are iD place and blrn adjusting screws iDto pressure plate.

Place pressure plate as assembled iD a press with the plate down,

Place springs on pressure plate and spring plate on springs. Be sure spring plate 1B aligned with levers,

Compress the springs eIl.ougb 80 the links can be installed in the spriDg spring plate.

move links. 4. 5.

Release pressure and remove spring plate and springs. Unscrew adjusting screws from pressure plate. Lift pressure plate frame from

pressure plate. 6.

Do not .remove adjusting screw or clip from lever unless one of these parts is to be replaced.

Further disassembly of the frame is not reoommended because the frame and levers are serviced as an assembly only.

Inspection 6.

Place pressure plate on surface known

The pressure plate must be replaced if

to be "flat. Turn the adjusting screws

the clutch surface is badly beat checked or warped more than .015" (0.381 mm),

as required untU the dIstance from the top of the levers to the table 1s2" :lo .031" (50.8 :lo 0.,87 mm), Figure 3. Then tightEn the lock nuts.

Inspect the pressure plate frame for distortion and signs of cracks. The tnOUI1ting flanges should be even within ,015" (O.381 mm). Also check levers and pinS for wear.

Check the springs fur distortJon and signs of cracking;

replace if either

{50. 8 ~. ""' ~

condition is present. If spring testing equipment is available, cbeck to see if springs meet the following 'specification: compressed length of 1.685"

IU'U

Figure 3

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6406- 5

•

~: ::~~E PLATE

3. PIN (3) [ PLAT[ f1WI£ 4. "ASHEII:(l}

5. LOCI( MtT ( 6. CLIP (3) 3) 7. ADJUSTING

8. LEVER (3l SCRfW

9. LINK (3)

10. SPftIN6 (6' II. SPR ING ...

,-"

"'~

FIgure 4 - Pressure Plate

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Section 6410 TWO SPEED MECHANICAL SHUTTLE

JICase

Rae 9-79116

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6410-2

TABLE OF CONTENTS o.nel1ll I"fonnetion .' .................................................................................................................. 3

Specia' Tools ............................................................................................................................. .. 4 Removal and Separation of Housings ................................................................................. : ..... 5-7 Servicing the Mechanical Shuttle Housing

•

,. ~

Diassembty ........................................................................................................................ 8·'0 Countershatt Installation .................................................................................................... 11·13 Reverse Idler Shaft Installation .......................................................................................... 14,16 Output Shaft Installation ............. ................................•..................................................... 16,18 Input Shllft Inatallation ................ , ..................................................................................... 19,21 SeJvicing the Dual Range Housing ~ ..' Disassembly ............................................. .... ............. ......................................................... 22,24

Countershlift Installation ............... ,.................................................................................... 26,27 Output Shaft Inltallation ................................................................................................... 28,31 Range Shift Rail and Fork Installation .................................................................................. 32,33 Shuttle Shift Rail and Fork Installation ..... ............................................................................ 34,36 Cover Installetion ........................................................... .... ............... ......................................... 37 Neutral Start Switch Installation and Adjustment ................................................................. 37,38 Mounting Houling' to Engine Flywheel ..................................................................................... 39

..,.:

.. .. ..

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641().3

GENERAL INFORMATION

THIS SAFrJV AL[RT SYMBOl INDICA fl S IMPOR lA.VT SArl;Y MFSS~G[S IN THIS MANUAL VIIf{I"N YOU SEE fillS SY,,",,'BOL CAINfUllY RCAD THE MISSAC[ r}fAT IDUOWS AV{) n( A/FRT 1n THE POSSIBIliTY OF f-'l-FSDNAL iNJURY Oil DEATH

CLEANING - 810.," cle.n the oompkUo exterior of the two speed f1'IeChwttc.1 mUftis

steam cNianlng. Do not use ceUltiC soda so-

BEARINGS - Check bearings for free smooth action. If bearings lulve a loose fit or rough action, raplace the bearing . Always replace cup and cone as a set, nlver just one part of iii bearing . Wash bearings with a good aolv8flt and let lir dry. DO NOT SPIN DRY,

lution for at•• m cleaning. All parts should be dried and lightly oi~ after cleaning. Oil pa ...,.a (18" 1M cle.ned with compreued air. Bearing • •hauld be e~.n.d In mineral spirits and lightly oiled.

To facilitate assembly in many areal, bear· ingl may be heatad. This will upend the bear· ing inner race. eliminating tile need of a hydraulic pre.. when Initalling bearings over shafU.

hou.mgs betOI'1l any service worit i, perfor~ . All metallic partll. except bearings. ahoukl 1M clolonod in mi,.....1 spirits or by

INSPECTION Inlpgction of .11 parl$ should be made when di .. ssemblV is required. Any part that ShoWI allle.Hive we.r or damage

mult be replaced . Small nicks or grooves can be ,.moved in mo.. el.1 wkh • hone or croCUI cloth . Thorough vitUlli inspection for indiQtions of wear, Itrell, pitting and tha replacement of IUch parts as necessary will eliminata oo.tlv and avoid.t».e unit failure . GEARS - Inspect all ge"s for wear and dam· age. G_rs which are wom, ridged or scored muat be replaced . NOTE: If it i, nee..sary to repiaCil either the bevel ge.. IdiHerential ring ghrJ or pinIon shaft, the bevel geer and pinion shaft must be Alplaced IS iii rNltched

NEEDLE BEARINGS . Atw.y, remo~ .ny burrs in bore or edge of bore before pressing in n_dle bearings. Lubricate inside and out· side diameter of bearings with • lubricant befo,. pre..H1g into place. When pre..ing needle t.e.ings into place, II· ways use a bearing arbor. PlaCil bearing on arbor with stamped end (end with numbefl' against stepped shoulder of pressing arbor.

M'.

SHAFTS - Inspect ,II shaft. for wom, pitted or broken spline.. Also, check tor damaged beerlng and oil _II 'UrfIOOI on .hlft• .

•

OIL SEALS, "0" RINGS AND GASKETS When installing any part., elways inltall new gaskets, oil seall and " 0" rings. Lubriclte rubbing .urface of all lip type ..als with a lubricant before instaUation.

) •

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6410-4

SPECIAL TOOLS

u 015044 NEEDLE 8lEAfUHG DRIVER

015021 NEEDLE BEARING DRIVER o~

THERMO MOUNTER . MODEL ELECTRONIC DESIGNS. INC. 11'14 N. 62ND STREET MILWAUKEE. WIS. 5321'

TO ,

MICROMETER

"e"

SHUTTLE RAIL PILOT SLEEVE

TA""ND

FOOT POUND TORQUE WRENCH

~ I

-I 1-'11"

RANGE RAIL PILOT SLEEVE

....TT£Ry POWfAED nST .

LAMP OR OHMMETER

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SERVICING THE TWO SPEED MECHANICAL SHUTTLE Removal and Separation of Housings

DllCOnnKt drive shaft. wi .... and Irnkage to the shutde boxes.

Tum clutch th,ow-out shaft and remove the R.mow bolt. retaining flywheel houllng.

.hutt~

boxes to engine

throwout

urn..

c To .MOII Of repa.ce clutch yoke the Imgi~ muse be removed from the fty.yheeI housing, ....

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fer to Section 2060.

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6410-6

Shuttle box.. removed from unit.

Remove the neutnl start switch.

Remove the breather tube from top cover.

Remove tha top covers from mach.nigl .... uttle and dual rang. housings.

...

M0Y8 shift rllil so that the detent bell is in the reWI'M detent of shift rail. MaUll", betw. .n shift'-f' fort!; and housing as shown and reconl

me8 _untment. to UN tor a.ter installation ptOcedunJ_ Remove lodcWire and setsc:rew securing shuttle fOfte to shift rail~

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"'"

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6410Âˇ7

Cover the detent ball opening in tran..xle c..e and drive shift rail from detent section .nd ... move shift rail with steelw..... r and nyton washers.

Remow the shunle shift folic.

Remove the bolts whklh hold the two housings together.

Separate the two housings. To service the mech.nical shuttle ....mbly proceed .. follows Of' proceed to Step 77. P.ge 22 for ..rvicing the dual rang. . . . .mbly.

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&110-8

Service the Mechanical Shuttle Housing

Disassembly

Pfece the shuttle box on end.

~nd the thin portion of idle shaft locknut back out of the shaft slot.

Remove the bolts securing throwout spindle. Remove the idle shaft locknut.

Remove the clutch throwout spindle.

Install a #10-32 x 5" threaded rod in idler shaft end to aid in positioning shaft so that input shaft can be removed.

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6410-9

Push

id~r

shaft down into shuttle box.

Remove the input shaft assemblv.

Remove ..,ap ring securing synchronizer and gears to the output shaft.

Tum shuttle box up on its bottom or side.

Input shaft removed from shuttfa box. Remove output shaft and gear from shuttle

bo,.

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6410-10

SvnchroniHr. shuttle gear and output shaft removed from shuttte box.

Drive the countershatt from shutt.. box.

Remove countenhatt gear cluster. Remove threaded rod from idler shaft and lift out Ihaft.

Shutde boll: completely disassembUtd. Remove the countershaft collar shim â&#x20AC;˘.

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6410-11

Shuttle Countershaft Installation ____ .031" THRust WASHER

@() .," - .....oaT , . ., , "

NEEDLE THRUST BEAJlING

/~C6~

NEEDLE BEARING CLUSTER

/~~

QEA"

.""u ..."••

.... \

~oo

' " r" ,

SHUTTLE HOUS1NQ------

o o

~: @;

.126~

THJlUST WASHER

o@/" /.031~ THRUST WASHER

O@ ~

NEEDLE THRUST BEARING/

COUAR

COUNTEJlSHAFT.............-~ ~ SPlJlOL JlOL1

PIN~"/(?\ SHIM

InmaU collar (tapered 0.0. end tOWllrda Bluitt) on countershart. making sure retaining holes are aligned.

GROOVe PIN

Secure collar to shaft with splrol roU pin.

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6410-12

STEP 39

Using G15021 driver. press needle bearing into gear cluster. NOTE: Place bearing on driver with stamped end (end with numbers) against stepped shoulder of driver.

Thruat washers and needle thrust bearing in-

stalled in case recess.

u Install gear cluster in shuttle box. NOTE: Large gear end on top of thick thrust washer. Tum gear cluster over and install a needle bearing in this end also.

Install a thi!) 1.031 ") thrust washer. a needle thrust bearing and a thick (.125") thrust washer in case recess. NOTE: Thin thrust washer must be installed next to the case.

Install a 'thin 1.03'''') thrust washer., a needle thrust bearing and a-thick (.:126j thrust washer on cauntershaft. IMPORTANT: The thin (.03''') thrust washer must be installed next to the collar.

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6410-13

Check shaft end play by using • straight .etg_ and fMler gluge. Me. .ure the distance bet· ween straight edge and counte,.haft coliar.

Inatall countershah through case opening.

STEP 43

Install two groove pins in coliar and case opening •. Tap pin. down into place until they are flulh with colta •.

From feeler gauge reeding. Step 44, subtract .004 to .00g" and provide a .him pack guard to the remainder of feeler gauge reading .

.031 - THRUST W;'"'' '' ,- ~ ' ." "' - THRUST WASHER T'liRUST

NEEDLE

IEARING

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6410-14

Reverse Idler Shaft Installation

REVERSE IDLER SHAFT

c:(" . . . . . . . . "'N. / 04t)~ ...----'NAP "'NG

REVERSE IDLER GEAR

"0"

'0"" BEAR'NG/ '()( .... \ I I I

Place bearing in Idlar gear.

....

Place bearing retainer snllP ring in gear re-

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64lo.15

Install • new "0" ring on idler g•• r shaft, Coat "0 " ring and shaft with a thin film of TCH oil.

Inltalla #10·32 x 6" threaded rod in Ihaft end.

Position idler gaar down and to one side of housing. This will .110..... room fo, input .h.ft in-

Place idler geor on sheft. NOTE: Snap ring side of gear mult be towards threaded Ihaft ond.

mUation .

~~!~:;= s"" RING

Place id&er gear and shaft In ,huttle box.

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6410·16

Output Shaft Installation OUTPUT GEAR

Ir· '~/ / I

THRUST COLLAR BLOCKING RING

() ( ) /

S"'FT PUTE

~/............ RfT...INER

I "

,.......-SYNCHRONIZER HUB

(J."

SN...P " I N G . . . . . .

..........."fT...INER SPRING

THRUST COLLAR .............

r·,O \

@ /

.:f.' N G·...... lIJ.......

()

~ ____

~~~~W"'SH!"j /

~...

.........

I ' ~"'"

(~~c

lie ,..

SHUTTLE HOUSING

'-...I ! "'//

ou",rr" '"'.FT8EARING

Haat b.. ring on a baaring haatar and instaU on output shaft. NOTE: Snap ring end of bea,ing must be up,

IILOCI(ING RING

j I I

......

/~,;

V',

I'...... . . .

IIUSHING

' / '~ ............ ,~

OVTPUT SHAFT

SPRING

....

I "'J

. .'l\ SELECTIVE SN...P RING .078, .080 .. 083•. 0117 • .09'~

Tum range input shatt over and in.,.11 nMdIe bNring in shaft bore. NOTE: Press nudle bNring to a dapth of .100" below ga.r and face. Pra.. on stamped and (and with numbers) when Installing need.. _ring.

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6410-11

•

IrwtIIll thrurt collar and bfonu WIIshe, OIl output .....ft. NOTE; ThnJat ~ol"r must be Installed ne:ll:1 to bearing.

Install the

.pined

thrust

coUar on

output

'haft.

o Piace lIynchronil.r ,Ieev. inside of hub. Slide output gear bushing on '.tn.ft.

Irma' the three sfllfter pqte& in aynchronlur SlJIrt-the output shaft into .hunle houafng and IMUlII ou1put gea, on ahaft.

efeeve

groov...

•

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6410-18

Ratain the shifter platss in place with ona retainer spring.

Turn the synchronize.. hub and slee.... over and install the other retainer spring.

M_sure .synchronizer sleeve hub length noting which sid_ has short hub length and

place blocking

rings

synchronizer

hub.

Install synchroni;z:er ....mbly on shuttle out-

put shaft.

IMPORTANT: Short slâ&#x20AC;˘â&#x20AC;˘ve hub side of synchronizer must face forward . . . . Stap 63.

Install synchronizer and shaft retaining anap

ring. NOTE: Snap ring i. provided in .076"

.080", .083". .087" and .091" thicknen. install snap ring that will provide a minimum

amount of synchronize, end play.

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Input Shaft Installation

J'~' .HAn

HOUSING GA'"''

o".~~~ /

THROWOUT SPINDLE

H..t !»Inn; on a buring h•• ter. Inmll tM.r· tng on 'npf.ll ."att and ..... in In plao- ..... i1tt snap ring. NOTE. Snap ring end of bearing must be up.

Pres. needle bearing Into Input thaft until bMrtng i. t1Wn with wft Moulder. NOTE: Pr ••• on .umped WJd (end with numb.r) whtn

inl1llllfng IMI6dle beering .

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641()'211

InlUlI input shaft in shunle housing opening.

Rai.. and pull rever.. idler gear and shaft into position. Install ,haft retaining locknut.

Stake the thin portion of locknut into shaft slot.

Install a new housing gasket.

•

Remove th....ded rod and tighten locknut .... cu,..ly.

Pre••• new oil sea' in clutch throwout spindle until il bottoms.

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6410-21

Install the clutch throwout spindle Ind torque spindle reteining bolls 35 10 42 ft. lb â&#x20AC;˘.

Shuttle housing luembled, 188 Step 131. Pege 34 tor joining to renge housing end inAallation of shift ,.11 and fork.

()

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6410-22

Servicing the Dual Range Housing Disassembly

Place the dual range housing on a suitable work

Drive ahift rail through ,hitter fork.

surface.

Remove the ,hifter fork from range housing. Remove the, countersnaft shims.

STEPÂˇ'.~I

Remove shifte, fork retaining set screw.

Cover the detent opening when removing ahift rail. this will prevent the pouibility of detlltl1t ball dislodging and sending cup plug flying.

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641(}'23

Remove the output shaft yoke reteining nut.

Oust cover and oil seal aSHmbly removed from output .haft.

Ramove the output yoke and hardened wesher. Rem0V9 the large snap rl"lg retaining bearing to ral1ge housing.

Remove dust cover and oil seal assembly. Tum the range housing over and remove the shaft geer reUllnlng snap 'ing.

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Remove the output shaft and gears from range hOUling.

Remove elqNMion ~ug and drive counterahaft from housing.

Output sheft.and gears removed from dual range

Remove the countershaft gear cluster.

housing.

, <

â&#x20AC;˘

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6410-25

Countershaft Assembly and Installation .03IM THRUST WASHER

,..~

NEEDUi THROST BEARING

.126~ THRUST WASHER

\...

J~~/

NEEDLE IlEARING

r: ~ / ~

..... ..... ...............

t"'":l\ ......

\ , ,, EXPANSION PlUG

b, ,

bottom.

.12S· THRUST WASHER

NEEot.f ntRUST tEARING

@~/.031~THRUSTW.... HI!R

,, ,

I I

•

Tap roll pin into counte,.haft collar unbl they

NEEDLE tEARING

@, ~

CLUSTER GEAR

Align retaining holn and place collar on count.rstt.tt. Roll pin side of collar.away from shaft.

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6410-26

Install collar to shaft retaining roll pin.

Using drive, 016044. install new needle bearing in ge.r clulter. NOTE: Press on the bearÂˇ ing stamped and lend with numbers) until bearis even with ge.r chamfer.

Tum ge.r cluster over and install another lee Step 98.

needle bNring in g.. , bore,

Insull a thin (.03'''' thrust washer, a needle bearing and a thick (.125") thrust washer in housing recesi. NOTE: Thin (.031 "J thrust washer mUlt be next to the housing.

Install the g8.r cluster Ismail gear down) in housing on top of the thrust washers and ne.dle bearing.

Place a thiclc (.125", thrust wUher, a needle bearing and a thin {.031", thrust washer on

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•

I~'

countershatt through thrus1 wathen. bearing. and gear cluater.

!"rom feeler

~uge

....dlng. St.p , 02. subtract

.004" to .009" and provide. shim pack eqUilI to tM mlNlln., of 1M.. , gauge ....dlng. In· Slalil tiM shim J)IIcK 0 .... collar roll pins.

c With • straight edge and feeler "auge. mealur. the dt.une- berw.en the stJ1light edge and coun·

Tum houling over and Install a new expansion cup plug In shaft bora .

t81'Shaft colla,.

..j

.031 - THRUst WASHER

.031 - THRUST WASH" ••

NEEDlE THRUST .EA.'."

/1 ""ED" THRUST IlEARING

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6410-28

Output Shaft Installation

RETAINING NUT

I ~@

OUTPUT GEAR

HARDENED WASHER

/GeAR

. //"OUTPUT YOKE

Ci @_O",SOAL

SU::EVE

~~~e./

COlLAR CARRIER

SHIFT COUAR

SN.. ",NG

/o~

OUTPUT SHAFT/

'I""')

SNA:~:; BEAR'NO /~~, _ :.t:~~Y".~.,.,. SNAP RING

THRUST SPACER

;(l)

~ ," fJ-,' I~ I' lIANGf

•

/l\

HO~ING.

SEI.£CTNE SNAP RING

-07., .080. .083 • .087 • . 081 M

Install. SNIp ring in output shaft inner housing

""""',

InstIIll • SNIp ring in output aIlaft re.r groove .

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6410-29

He.t burin; on • be.,in; heawr and instaU on output shatt, making Iur. besring contacts IMP

Start the output shaft into range houaing end in.tall output ge.r and sleeve on ."aft.

ring.

o Inatall the tflru.t spacer on range output

wft.

InstaH tM ..,ift colle, c.lrrMr In.. of the Ihlft coI'la,. NOTE: 011 groove Iicte of CIIrrier on aide •• bevel.ct I. D. of MItt col·

. ,.

"mil

in.uJI the splinad ,!eew In.ide of the output Irwtllil .. itt coa&. and ClImer on range out· put aMft. NOTE: 011 groove aieM of c.m.r

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Drive output shaft into housing bora until bearIng makas contact with inner retainer snap ring.

Instlill ....cted snap ring, Step 114, on range output shaft.

c Install outer bearing retainer snap ring houling groove.

Salect a snap ring that will provida a minimum amount of g_' backlash. NOTE: Snap rings a,. provided in .076", .080", .083", .087" .091" thicknesses.

Pr... a new ...1 ....mbty in housing bant, until ... 1 f.ce i. .190" below housing face.

Install range output shaft yoke. NOTE: Coat yoke 0.0 .â&#x20AC;˘_ling surface with clean TCH oil.

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641<>-3'

Install harcMned w ..her end yoke retaining nut. NOTE: Due to the high retaining torque vatve of nut. do not torque nut until hou.ng Is In-. stalled on engine flywtteel hou~ng. Me .Step 1152, Page 39 . SNAP RING

f:2

....

"L,

•

""",

',;

()

" • <

•

, 0

•

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000-32

Range Shift Rail and Fork Installation _ _ CUP PLUG

RAIL OIL SEAL

RANGE SHIFT RAil

DETENT BAll.............

...........

• - - - - LOCK SCREW

D",NT ' ....,NG-i. •

" ~:o:

Coat the 0.0. of 8 new range shift rail 18111 with #2 Permatex.

O""-LOCK WIRE

•

- - - SHIFT FORK

Instell rail detent spring and ball in fanga housing.

, Inltllll rail ... 1 in housing bore until it bottom •.

Insull pilot ateeve. . . . Page 4. to retain detant ball in po.ruon.

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6410-33

Presti range shift rail (flat side down) part way into housing. forcing pilot sleeve out.

Lockwire set screw in place. Make sure lockwire does not interfe,e between fork and housing during ahifting.

o Install range shifter fork in housing -and preIS shift rail through fork. and the rest of the way into housing.

Install cup plug in housing detent opening.

Range hOUsing assembled. Install fork retaining set

~raw.

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Shuttle Shift Rail and Fork Installation

u RAIL Oil SEAL

1<rrnE s.,...

RO" LOCK WIRE

NYLON WASHERS

STEEL

WASHER--(j.~\

••

-LOCK SCREW CUP P\.UG

SHIFT FORK_

a_DETENT

0All

'""'-. DETENT

• e

SPflING

o HOUSING

GA"'"

. tJ :

SHUTTLE HOUSING

1"'-

Install 8 new shuttle shift rail ...1 in range housing bore until it bottoms.

Install a new housing to housing gasket.

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•

, 641().35

, In.~11 housing retainer bolts and torque boltt: 35 'to 42 ft. Ibs.

Inatall .... uttte detent spring and ball

NYLON WA.SHeRS

"All

Suet( the steel washer lind nvlon weiher' to mitch' m . .surement taken in Step 11 of dis· assembly. Use .onty one steel waahef and •• meny nylon wa.tMtr. II. required. NOTE: Do not over .tack. measurement. Install ..1ft rail part way into housings and install the steel washer to ahaft. ·then nylon walhers .1 shown in Inset. Install shifter fork on snychronizer unit.

In81ll11 Pilot sleeve. see Page 4, to rebtin detent baH In position. see Step 1315. ,,-,

Press shift rail through fork lind foree pik)t sleeve from houling .

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6410-36

Inaul! shuttle fork retaining set .crew.

Move the Ihitt rail into rever •• detent and check to make lure that there is enough nylon w •• h .... to pt'event ovenhift. If it ha. to btl forced into reverse detent. nylon washer may have to be removed.

Lockwire set screw in place. Make sur. lock· wire does nOI int.rf.... between fork and housing during shifting.

Install cup plug in shuttle housing detent opening.

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6Uo-37

Cover Installation and Mounting to Flywheel ,"'ATH"

---fv~

! "NG',OU"NG COV'. I I

SH"""

HOUSING COVER

"0 ..

Install housing covers IIfIU torque taining bolts 17 to 20 ft . Ibs.

00'IItI,

re-

START SWITC H

SHIM

Inltall neutral SUII'! .-itch in housing an4 pl.eft "U" shift leve, in neutral.

Apply .. thin bead of RTV gasket compound (Cu. No. M20704 Dr M20705)to housing cover mlting surfaces.

Connect. 12 voh t.lt lamp Of an ohmmeter

ac:ross .witch terminals. Tum switch inward until the test lamp lights Dr ohmmeter registers a reading.

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6<10-38

Pllice the shift lever In ge.r. Check to Me that tol1 lamp goes out when in gear and comes beck on when...in neutral; the ohmmeter if used. should not register when in gear and should register when in neutral.

Remove the switch lind add required shims. Shims II" available in two lims. G49401 r.OO6"} and G49402 (.010").

v Apply #2 Permatex to neutral start switch thread. and Inltall switch in housing.

U"ng a feeler glluge, measure the distance between the switch and housing for the amount of shims required.

Inatall breathe.. tube in tllnge housing COWf".

â&#x20AC;˘

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g_,.

Lock "'uttio end ,ange up end torque output yoke re1ainlng nut 200 to 240 ft. 11M.

"",

•

InnaH ahunle box" on _"'iIln. ftywtlMl ttou.. Ing.

Mechllnicel shutde tJ1InwniMion • ...,bIed to engine flywhMI hou. . ..

-•

.;"

To.que Ihuttle box to 3& 10 42 ft. lba.

•

_•.. /. .:.....

·~.o

hou.tng bolts

•

. "" -.... ... ...

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•

6410-40

NEUTRAL ""RT SWITCH RANGE HOUSING ~O'V'R

SHUTn.E HOUSING COVER

'-'

•

NOTE, lIM

c...""", __

c...

'" ...... .. ........

' •• 'Ileal.....

.... . - '"' _ _ Itt- ... ..nits

lit'"

o' ...., ,.... .w.

.......

w;1Noo.H

................,.

-,.

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Section

7106 BRAKES (PEDALS TO TRANSAXLE)

J I Case A Teml8CO Com pa ny

C. E. Div. &-66015 _

. . U.$ .....

February 1976

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_- .__ -=:

TABLE OF CONTENTS Master Cylinders

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .

"--.

. . . . . . . . .. . .

7106-3

ReDlOval ••••••••••••••••••••.••••.••••..•••••• _. • • • • • • • ••

7106-3

Disassembly, Inspection and Assembly. • . . . • • . . . . . . . . • • • • • • . • • • • ••

7106-3

Installation . . . . . . . . . . . . . . • • • . • • . . . . . . . . • • . . . . • . . . . . . • . . . . 7106-4

Brake Pedal Shaft Removal on Power Shuttle Machines ..•.••••••.••.•••••. 7106-5 Parking Brake Control

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .

NOTE: For all other brake service, refer

7106-8

to Section 7025.

;,. -

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7106- 3

MASTER CYLINDERS Removal The following procedure applies to the power shuttle and mechanical shuttle machines. Refer to Figure 2 or 3 depending on which machJne you are working on.

Remove instru.ment panel as instructed in Section 8004.

Remove stoplight switches and brackets as an a9semhly If so equiPped.

Remove cotter pln and clevis pin from

cylinder to be removed. The cleviS pln for the right-hand master cylinder on power shuttle machine is held In place with E~cllps; remove the inner E-cllp to remove clevis pin. master

If equipped with stop lights.

NOTE ;

all

clevis

pins

are E-c1ip

â&#x20AC;˘ fi.. ' 8"~'

retained.

Dbconncct brnke line from master cyl -

inder to be removed.

1. CAP

2. GASKET

Remove

nuts

3. MA.SHR CYUN DE R

(lDd lock washers (rom

4. VAlV( SEAT 5. CH EU VALVE

mounting bolts.

1. PRll'ARV CUP 8 . P1Sl0tl 9. SN AP RING 11). ~UBBÂŁR 8001 II. PlIS~ R{)D

6. SPRING

Hold master c)'llndel" with one hand and remove the mounting bolts. If bolts are

completely removed, the spacers will fill! to the floor plato,

Disassembly. Inspection and

Figure 1 - Master CylJnder 5.

Inspect the cylinder bore for pitting, scoring and rust. Use a cylinder bone to clean up the cylinder bore if pi.tting or scoring l.a light. Replace master cylinder if scoring or pitting is excessive.

mspect the primary cup. piston, check valve and valve seat for wear and damage that could result in leakage. A repair kit containing these parts is available.

Inspect spring for signs of cracking and distortion. Replace spring if either condition is present

Lubricate the cylinder bore. piston and prinary cup with clean brake fluid.

Assembly 1.

Empty master cylinder reservoir and mll"ter cylinder in a viae.

~ecure

1S1iOo!J

Remove rubber bOOt from master cylinder and removc boot and push rod assembly. Do not separate the clevis and push rod unless one of the parts is to be replaced. Before !Oeparating the parts. measure the overall length and assemble the parts to this demension.

R emove snap ring from cylinder IxI re and

remove the piston. primary cup. spring. check valve and valve seat.

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7106-4

install valve seat. check valve. spring. primary cup and piston In cylinder OOre. Secure parts in place with snap ring.

10. Place push

rod

Place the remaming spacers between the mounting pl ate and r!ghthand master cylinder and push bolts through master cylinder.

d..

Install lock washers and nuts on mounting bolts and tighten nuts.

Attach push rod clevis to brake pedal

in piston and attach

ooot to cylinder.

Installation 1.

If installlog master cylinder on a power

with pedal with clevis pin and secure pin in place with cotter pin or Eclip if equipped with atop lights.

shuttle machine:

b. c.

Engage push rod clevis with brllke pedal and instu.J.l mounting oolts with spacers between the master cylinders.

Connect brake line to master cylinder,

FnI master cylinder and bleed brake as instructed in Section 702 5.

Install lock washers and cuts on mounting bolts and tighten nuts . Secure clevis to brake pedal. If Installing the right-hand mastercylinder. push arm on clutch cutout s witch forward and install the c levis pin. The switch arm must be in front of the clevis pin. Secure clevis pin in place using cotter pin or E-

Definition of Brake Pedal Free Trllvel. Brake pednl free travel Ie tbe amoWlt of brake pedal travel before the m aster cylinder puSh rod contacts pIston In master cylinder. NOT!!:

c"".

NOTa:

pedal free travel must remain within this specification wIth the pedals locked together. If free travel is not as specifiod, loosen lock Dut on clevis and turn push r od as required and tIghten clevis lock nut. Then check free travel.

If equipped with stoplights.

both clevis pins are E-clipretained.

If installing master cylinder on a mechanical Shuttle machine: a.

Start mounting bc>its into left-band

Check to see that the brake pedal has 1/16" - 3/16" (1. 6 - 4.7 mm) free travel. If clevis locknut is loose. tighten nut before checking !ree trll.vel. Brake

Install s toplight brackets and switches

master cylinder.

if so equipped. Be sure the switch arms are to the front and on top of the clevis

Place the two short spacers between the master cylinde r and mounting plate. and sturt oolts into mounting plate.

pins . 7.

Install instrument panel as instructed in Section 8004.

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7106- 5

BRAKE SHAFT REMOVAL ON POWER SHUTTLE MACHINES 1.

Remove InstrumeDt panel as i.nstn1cted Section 8004.

Remove floor plate.

Remove brake lines between master cyI1nders aod connection just below floor plate.

Disconnect tubes tit steerlng control valve and close openings with caps and plugs.

Disconnect Shuttle and throtUe lillkage from their Shafts. Pull shafts up and tape to steering column.

Remove double nuts from fuel tank strap s"blds.

Re move firewall retaining screws.

Remove brake pedal return sprIngs.

Remove pedal Shaft bearing retaining nuts and bolts and remove outer bearing.

10. Loosen set s crew in master brake pedaL Then remove c levis pin. clevis rod. washer and spring. 11. Remove master brake pedal and bearing from shaft.

12. Loosen set screw in brake pedal lock plate. 13. Move brake pedal lock plate to expose Woodruff key. Do not attempt to drive shaft out of brake pedals without removLng the key; the pedals do not have a keyway. Use a chisel to remove key from shaft. 14, Pull shaft from brake pedals and pedal lock. 15. Reverse stops 1 through the brake shaft.

to install

16. Bleed brakes as Instructed in Section 7025.

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7106-6

..,

ISIW'

Figure 2 - Brake Pedal and Master Cylinder Installation with Power ShutUe

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7106- 7

Figure 3 - Brliku and Clutch Pedal eatallatiorl with Mechanical Sbuttle

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7106-8

PARKING BRAKE CONTROL

"" !

Figure 4 - Parking Brake Control Installation

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Section

7122 SELF ADJUSTING DIFFERENTIAL BRAKES

J I Case

RI(: ' Â· 79245

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TABLE OF CONTENTS Removal of Brake Housing ...•.........•..................•......................................................................... 3 Rebuilding Brake Disc Assembly ............ ... ..........................................................................•..... 4,5

Brake Uni"9 Removal" ....................•........................................................••.........................•....... 6 Actuator Removal ............................•..............•................•.•......................................................•. 7

Rebuilding Hydraulic Brake Cylinder Removal and Disassembly .........................•...................••.•....................................................... 8 Assembly and Installation .................................•.....•...........................................•............•... 9.10 Brake Housing Reassembly ................. ...... .................•.......................................................... 11-13 Installation on Transaxle Housing .....................•.......•.•.........•......•......•........•....................•.... 14.15

SPECIAL TOOLS

3 / 16 SLOTTED SCREWDRIVER

RIVET CUNCHER • NO. U67A·2

9/64H RIVET CUNCHER • NO. 6667A.1

McMASTER .CARR P. O. BOX 4366

CHICAGO. ILL 60680

FOOT POUND TORQUE WRENCH

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SERVICING THE SELF ADJUSTING DIFFERENTIAL BRAKES Removal of Brake Housing

Remove the brake 1811er return spring .

Brake houaillg removed ffOm ttansaxle cue.

Remove the ule houling bolt securing retum

Remove the brake disc alsembly from the diff8.,,"t .. 1 skte gu,.

Epting braclfa t .

Remove brake housing retaining bolts.

Self

adj~lng

brake auembly ,."oved from

tranaaxle,

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=-4 Rebuilding Brake Disc Assembly SPlINED OISC

STEP 9

"-..

Check discs and lining for excessive wear. war-

page. loose linings or oil saturation.

ACTUATING BALL

~"n,.,nNG

DRUM

SPRING

If new linings are to be installed on discs, remove old linings and proceed as follows : ,. Clean the lining mating surfaces.

2. Clamp new linings in place, being careful not to damage linings.

3. Push new rwets through holes from lining side. 4. Form rivet head with a 3 / 16" tubular rivet clincher. McMaster- Carr No. 6667AÂˇ2 .

NOTE: If VOU do not have the proper dies and punches to perform a brake relining job. Take the parts to an automotive center that performs brake relining service, this will prevent damaging linings due to the use of improper tooling. or install new brake disc assembles that have linings already installed .

â&#x20AC;˘

'-.-

Unhook brake disc springs with a small slotted

screwdriver.

Install the four baUs in actuating drum recesses. NOTE: Check balls and drum recasses for roughnass and replace if necessary. Remove splined disc from actuating drum.

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7122-5

Inltall splined disc on actulting drum.

With â&#x20AC;˘ slotted screwdriver, hook spring ends over reu ining elrs.

---~

Insert brake disc springs in recess openings.

Brlke disc spring specifications: Free length ... .......... ............ ... ..... ... ... 1 .27 " Wire dia ............. . ........... .................. . 0 86" No. of coi ls .. .. . .... ... .... 10Âˇ 1 / 4 (9 active) Extend to 1.37" . ....... ..... 22 .5 to 27.6 Ibs.

Install brake drum and disc assembly on side gear spunes. NOTE; Splined disc; . . . mull be installed next to transaxle case.

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Brake lining Removal

Remove cotter pins securing band and link clevis pins.

Unhook band retum springs and remove bands from brake housing.

STEP 18 Check blinds and linings for ell:C8uive wear, warpage, 100M linings or oil saluration.

u If naw linings ara to be in.talled on bands, remove old linings and proceed a. follows: 1. Claan the lining mating surfaces. Remove braka Mnd anchor bolt. 2. Clamp new linings in place, being careful nOI to damage linings. 3. Push new rivets through holes from lining side. 4. Form rivet head with a 9 / 64" tubular rio vat clincher, McMa.ter-Ca". No. 6667A-l. NOTE: If you do not have the proper diu and punches to perform a brake relining job. Take the parts to an automotive center that performs brake relining service. this will prevont damaging linings due to the use of improper tOOling. or install new brake band assembles that have linings already installed.

()

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7122·7

Actuator Removal

ft_.

the .. If·.djusting rod ,end ..nove

,.t-

Removtl the roll pin retilining brake lever pin.

..... nut.

(.1 ReI1'Iow the

- g.

tnke. lev... pin from the brake

Remove the cam return apring end rod.

•

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, Rebuilding Hvdraulic Brake Cvlinder Removal and Disassembly

""",,.

Remove pilton ,.wining ,nap ring ffOffi cylinder body.

Remove push rod ITom cylinder body.

Remove pilton .....mbly from cytinder body.

Remove w ..tMr seal boot from cylinder body.

Blow out cylinder body witt. compreaMd air and check bore for roughn.... Hone cvtlnder bore if nece.aary to remove roughn....

Remove the bolt, .ecuring cylinder to brake

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7122-9

Assembly

1------ PUSH ROD ~-------S~B~

e,----o

SNAP RING SPUT BACK·UI' filiNG

0----- ··0" RING

@1-----~sroN i"'I~

In.tall new "0" ring on cylinder pi.ton.

___ CYUNDER BASE , - - - 8U:EDEA SCREW

( ; Install the apllt backup ring on piston next to the "0" ring.

I"autl

~. .d.r

acrew in cylinder Nu.

CI. .n end lubricete p£non .nd cylinder bore with cle.n bt-eke fluid . IMPORTANT; Do not

UN oil •• en lubricllting egent. Torque bINder .crew 10 to 60 in. lb•.

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7122-10

STEP

39 .

Install piston retaining snap ring.

Hydraulic brake cylinder reassemble( .

STEP40

Install a ew weather seal boot on cylinder body.

Plac

STe 38

STEP 41

nstall push fod hrough boo make. con act wit piston.

opening until it

brake cylinder on brake lever.

Hydraulic lever.

brake

cyliode

IOstalle

brake

=-11 Brake Housing Reassembly

;t"~~- CAM SPRING

SHOULDER BOLT

ROU P1N---o 8RACKET

ADJUS~NG

•

""'----.

CAM ROD

/ IA

~-8RAI(E CAM

"GD

RET\JRH SPRING OUTER UNItS

INNER liNKS

8AACKET--~ EXPANSION PLUG

RETRACTOR SPRING

<Y1~ U PERMATEX

AETltACTOR SPRINO

"" . . BAND

EXPANSION PLUG

ON THREAOS BRAKt: HOUSING

IMIaIi "00 retraotor spring. in brake cover r .

cease •. Band retr8ctor spring spaciflcations:

Inst8l1 a new actuating rod du" seal.

F.... ktngth ............... ~ ......................... 66" Wi,. die........... ................................. 060" No. of coil, .............. 5·3 / 4 f4-V4 activa, ElCtend to .74" ................•...... 9 to 11 lb•.

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Inmll e:xpension plug In spring opening.

Inst.1I cam return spring and rod.

Cam return spring specifications: Free length ....................................... 2.09" 0.0 .....................................................54" Wire dia. . .......................................... 086" No. of coila ................................... 15Âˇ3/4 E:xtend to 2.34" ............................. 14 lb â&#x20AC;˘.

Install brake lever on housing.

Install actuating rod with inner and outer band links attached to rod.

Install lev... retaining pin. aligning pin hole with lever hole .nd retain In place with roll pin.

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7122Âˇ13

In.tall a new "0" ring inside of adjuating ratchet nut and install ratchat nut on actuating rod.

Altgn blinds with attaching linb Bnd Install retaining clevis pins.

Pl8C41 brake bends In housing and -attach bind retractor springs to the band ears..

Retain clevi, pina in place with new cotter pins.

B.ake band, installed In brake houling.

Align pivot ends of bands and install anchor bolt.

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7122·14

Installation on Transaxle Housing

Install brake housing o ver drum assembly and torque retaining bolta 80 to 96 ft . lb • .

.37!in FREE TRAVEL

o o

Tighten the self adjusting ratchet by mOving brake lever up and down until tlMre ia .376" free trllvel at bl1lka cylinder.

CAUTION

r.III",,·

"'t

[fI'"

(r,IV"1 "(

IJ,.lX(' c,lmr/"r (INIIi! 't'sIIlt In no b'oINI' <JC{f{)/J wht'n ""I)fI'~"f"l IJf,,~e Pt'r/ ii,

Apply #2 permate ll to the f irst few threads of allle housing bolt.

Install brake lever retum spring.

allie housing bolt a nd s pring bracket. Torque ule housing bolt .. fo llows: Grade 5 bolt - 150 to 180 ft . lb • .. Grade 8 bolt • 220 to 264 ft. lb • .

Bl'llke lever retum spring specific.tions: Free length ............................................ 4 " 0 .0 ..... .. ......... .. .............. .. .................. 876" Wire dia ............ ............................... • 106" No. of coils ....................... ...... .. .... 21 -1/ 2 Ex.tend to 6" ............ ......... 34 to 37.5 lb • .

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7122·15

BAlke housing installed on trIInNJtl. cue. At· tach linhge .nd lines to brake cytinder. Refer

to Section 7106 for bleeding hydraulic br.ke

cylinder.

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Section

8002 TROUBLE SHOOTING

J I Case A Tenneco Company

19N:m

c. E.

Div. 9- 66015 ,untÂ£>

IN ........

February 1976

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8002 - 2

TABLE OF CONTENTS Specifications . . . . . • •.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8002 - 3 Trouble Sroot ing Chart .•... ... . . . . . . . ... . . . . . • .•. . . . . • . •..•.. ... 8002-4 Trouble Srooting the Charging Circuit . . . . .. .• .. • • •. .• • . . ••.... • . . . . . . 8002 - 7 Trouble Srooting the Starting Circuit . . . . . . • . . ..• . . . . . . . . . . . . . . .. . . . . 8002-10

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8002-3

SPECIFICATIONS Type of system. . ... . . Battery ... _ . . . ... . Alternator and voltage regulator . Starter , ... , . . . . , . , .. System cir cuit brl:.'aker . . . . . . . Accessory circuit breakers Headlights and taillights, backup alarm and horn if not equipped with beacon. , ... Bucket spool magnetic detent and clutch cutout if equipped with power shuttle . Floodlights ...

, . . . 12 volt. negative ground , one 12 vol t. to ~ectton 6005 , . . Refer to Section 8007 . Refer to Section 8006 . . . . . . . 40 amperes

. . .. . .. . ,

Heater and defroster

Windshield wipers Beacon and horn

Lights Cab headlight::! Canopy headlights. Floodlights

Combination flood W'ld taillIgbt Floodlight. ... Taillight Flasher . . . . . Stop and taill ight .

Beacon

Dipper . . . . . . .

... ..

.. .

10 15 15 15 15

amperes amperes ampe res amperes amperes :0.' 0. 4406 :-lo. 4411 :-.10, 4411

No. 4409X

. . ..

... .... .... . .. . . ... . . . . . . . .. . .

.15 amperes

~o.

1141

No. 1073 No . 1157 No, 4002 ~o.

4410

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TROUBLE SHOOTING CHART PROBLEM

POSSffiLE CAUSE

REMEDY

Run Dovm. Batterles

Grounded battery cable.

Inspect the cable from the battery positive post to the starting motor. Replace cable if insulation is 'NOrn.

Loose battery cables or

Inspect. clean and tighten or replace if necessary.

broken battery terminal.

,. >

Defective battery cell.

Test battery cells. Replace any battery with a dead cell.

Faulty alternator or regu1ator causing Insufficient

Any of reasons under Alternator Falls To Charge or Low

charging.

or Unsteady Charging Rate.

Grounded wiring in charging or starting circuils.

of a ground such as sparks.

Check all wiring for indication

Excessive use of starting motor or other electrical equipment.

Recharge battery.

Faulty starting circuit.

Inspect starting cLrcuit wiring

for grotmd. â&#x20AC;˘

starter Not Operating Or Fails to Operate Properly

heat. smoke or discoloration.

-â&#x20AC;˘

8002-4

Dirty battery top causing continued drain on battery.

Check for leakage on dirty battery top, Section 8005. Clean battery.

Shorted cell in battery.

Test battery, Section 8005. Replace any battery with defective celL

Faulty 40 amp circuit hreaker.

Replace circuit breaker.

Discharged battery.

Test battery. Ifnecessary, place on slow charger. If battery is continually discharged, test regulator and alternator .

Faulty battery ground wire.

Check for loose connections, corrosion or breaks.

Faulty wlrmg or loose connections in startmg circuit.

Use wiring diagram and trace out starting circuit checking for poor connections and broken or soorted wires.

Faulty key switch. starter button or neutral switch.

Replace parts as required.

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, 8002-5

PROBLEM

REMEDY

POSSIBLE CAUSE oll too heavy for

StLrter Not

~g:ine

OperatIng or PaUl tD Operate

outside temporature.

Refer to LubrJcantB and Fluids Chart In SecUon 1050. MaiDten-

anee and Lubrication.

Properly (Coot'd)

High resistance in starter polliUfe or ground circuits,

Teat c1rculta. For proceO.l.te and specUlaalions. see

Pace

8002-10,

Worn starter drive or ftywbeel

Remove starter and inspect

ring gear teeth..

toeth.

Loose starter mounting.

Inspect and UChten.

WOrn brwshea or faulty

Perform No-Load Test Il8 in-

&emamre or field coll or other defect in starter.

structeÂŤ( in Section 8006, If

starter faU, test. disassemble starter and repair as required.

Open, groWlded. or aborted windiop in starter motor

Check: solenoid, Section 8006. Replace solenoid If required.

solenoid.

Alternator Falla To Charge

Alteruator belt loose or broken,

TJ.eb1E1l to specifioatlon on page 8007-27 or replace.

Open or: hlgh resialaPce in

Rcfer to Alternator and

charging or around circuits.

Voltage Regulator TestiDg. Section 800 7â&#x20AC;˘

Wom. bruaheB or opeD brush leads or connections.

Replace bn.lShee or replace

Optm. ground or abort in stator wincUng.

Refer to Compoueot Testa in Sectbo 8007 Replace .tator.

Faulty regulator.

Refer to Alternator and Voltage Regulator Testing In SecWon 8007. Replace regulCltor.

Shorted or open rectifier diodes.

Refer to Componeot Testa in Section 8007.

Open. ground. or short in rotor (field) wlDdmg.

ReIer to Component Tests in Section 8007. A faulty rotor must be replaced.

Wires lnproperly conneoted a.1ter repairs.

Refer to wiring diagrams in SectiOn 8003.

Dirty slip rings or poor slip ring connections.

Inspect Slip rings. Clean or repair as required.

brueh holder assembly.

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8002-6 PROBLE.M

POSSffiLE CAUSE

Low or Unsteady Charging Rate

All of reasons under Alternator Falls to Charge.

Excessive Cha.rging Rate. Lights Burning Out

Improper or loose connections on alternator and regutator.

Check for proper connections and tighten ifnecessary.

Faulty regulator.

Refer to Alternator and Voltage Regulator Testing in Section 8007.

Batteries Require Too Frequ ".lit FUling

Faulty regulator permitting excessive charging rate.

Refer to Alternator and Voltage Regulator Testing in Section 8007.

Noisy Alternator

Defedive or badly worn belts.

Replace belts.

Misaligned or defective pulleys.

Align fan and alternator pulleys.

Loose pulley.

Check for sheared key or worn keyway, if used. Tighten pulley nut.

Worn bearings.

Replace bearings.

Shorted rectifier diodes.

Refer to ComponE!l'lt Tests in Section 8007.

Harness plugs not ..fully engaged.

Make.sure plugs are fully engaged.

One or more studs on plug broken.

Repl·ace harness.

Incorrect wiring.

Check wiring diagram. Section 8003.

Open or shorted wire in

Replace harness.

-. -

Continuity Test Shows No Voltage Through Wire Harness

•

REMEDY -

harness .

)"" ,I

.' ~'.-

I ,

,.-

•

.,;..

,•

• ••

.,--, f

r, I

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8002-7

TROUBLE SHOOTING THE CHARGING CIRCUIT The rollOwJug checks are ll.stcd in eaaeofperbrming and as near

&II

possible In t.be order

of malfunctlon occurrence, CHE.CX

DETAILED INSTRUCTKJNS

IvIsual check

Check for damaged wiring. loose aJ:d corroded terminal and harness plug connection. RepaJr

as required,

, Check: condition of battery

Check Can belt condition and tension. Adjust or replace belt as required.

Cbeck battery fluid level. Refer to Section 8005.

Clean battery top to eliminate voltage loas.

Check specific gravity. Refer to Section 8005.

Perform Capacity Test as instructed in Section 8005.

'. ,.

Replace mil!Jsma: fill caps.

Before contiDulng trouble shooting, install a

Check for bllttery cue damage that would result In fluid 1088 or admission of dirt Into cell(s).

battery post adapter, Figure 1. on the nep.Uve batte,ry poal 'I'beo attach cable to a.cIa.pter. Test equipment will be connected to the adapter later in the procedure.

~beck

voltage at alternator

Connect voltmeter negative lead to the alternator frame. Connect voltmeter positive lead to the Prestolite alternator Output terminal or the Delco-Remy alternator Bat terminal; battery voltage should be indicated. NO'I'E:Wf.Ej<j US.I~' S:u~ AOAP'TIR ANn SUN YAT -2.1 1W.... T1J~ ,""ETEII~m WrTtH TO - POSITIVE.

. Sll'ITIH

FIgure 1 - Battery Post Adapter

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8002-8

CHECK

DETAILED mSTRUCTIONS

Check voltage at alternator (cont'd)

If equipped with a Prestol1te alternator. turn key switch on and check voltage at the alternator Output. AuxUiary and Field terminals.

, ,

•

""1

Voltage at the OUtput terminal should be battery voltage to about 1/2 volt less than battery voltage.

Voltage at the Auxiliary terminal should be about 2 volts less than battery voltage.

Voltage at the Field terminal should be about 1-1/2 volts to 2-1/2 volts less than battery voltage.

•

Voltage at the Bat terminal soould be battery voltage to about 1/2 volt less than battery voltage.

Voltage at terminal No.1 should be about 2-1/2 volts to 3 volts less than battery voltage.

Voltage at terminal NO.2 should be battery voltage to about 1/2 volt less than battery voltage.

Check alternator output

Refer to Section 8007 for instructions. If necessary remove alternator for repair. Continue trouble shooting procedure.

Check wiring and terminal

Connect the positive lead of test ammeter to the alternator Output or Bat terminal and the negative lead to the battery post adapter. Figure 1.

Connect a carbon pile to the battery terminals. Make sure carbon pile 18 OFF bei:)re making connections .

Start engine and nm at 1/2 throttle. Adjust carbon pile to obtain a 10 amp charge rate on the test ammeter.

Connect voltmeter positive lead to alternator Output terminal and negative lead to positive battery post. The voltage drop should not exceed .3 volt. H voltage drop exceeds .3 volt, clean and

'., ~

;,.;

.' """

•

If equipped with a Delco-Remy alternator, turn key switch on and check voltage at the alternator Bat and No.1 and No, 2 terminals.

••

Continued on next page

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â&#x20AC;˘ CHECK

DETAILED INSTRUCTIONS

Check. wiring and terminal conductivity (oont'd)

tigbten cable connections at battery and starter

and check voltage drop agam . If voltage drop is stUl excessive, the cable must be replaced.

Move voltmeter poaitfve lead to negative battery post and neptive lead to the alternator trame. The voltage drop should not exceed .1 volt. If voltage drop exceeds . J volt. clean and tigbten all oonnections between the starter and battery

and check voltage again. If voltage drop Is aWl excessive one or both lVOund cables muat be replaced.

Check voltage regulator

Refer to Section 8007 for instructions.

Remove battery poat adapter after trouble 8hootln& is complete.

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8002-10

TROUBLE SHOOTING THE STARTING CIRCUIT General Inspection

placed. U the starter stIll fails to operate. the starter is defective and must be repaired or replaced.

Many starting problems can be solved by making the following cbecks: 1.

Check for open 40 amp circuit breaker.

Determine battery condition. R>e fer to Section 8005. Charge or replace battery as required. Clean battery posts and cable COlUlectors.

Inspect wiring for frayed insulation or other damage. Inspect all connections at the starter solenoid, key switch, starter button and ammeter. Clean and tighten all connections and replace any faulty wiring: Check to see that wirJng harness plugs are properly engaged. Also cbeck plugs for damaged or missing pJns and corrosion.

If the starter still falls to operate after remedyJng defects. check out the starting circuit.

'"CIAC. 8IDXÂŁR

Starting Circuit Check The following steps will locate defects in the starting circuit. The circuit may be

checked using a 12 volt test lamp or a voltmeter. 1.

Apply parking brake and make sure all controls are in neutral and pull fuel shutoff cable out.

Refer to Figure 2. Connect a jumper cable to the starter solenoid B and S termJnals.

If the starter operated properly. the starter and solenoid are good. and the problem is somewhere between the solenoid and key switch. Proceed to step 3 and check out starting circuit. If the starter failed to operate, connect the jumper cable to the B and M terminals on the starter solenoid. If the starter operated properly, the solenoid is defective and must be re-

Figure 2 - Starter Circuit 3.

Refer to Figure 2 and check for battery voltage at test paJnt 1. No voltage indicates the circuit between thekey switch and starter solenoid B terminal is faulty. Cheek circuit breaker, harness connecttions and wiring and repair as required.

Turn key switch on and check forvoltage at test points 2 and 3. Proceed to step 5 if voltage was indicated at each test point.

With key switch on. have someone bold starter button in and check for voltage at teet points, 4. 5, 6 and 7.

Checking the Insulated and Ground Circuits For these tests, the starter remains on the engine. A suitable tester (such as a Sun

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•

8002-11

Battery/Starter Tester) equipped with a volt-

GS D@D

meter • .ammeter. and means of varying the

load will be required.

Specifications Minimum cranking voltage •...•. 9.6 volts

Maximum voltage drop Insulated circuit .•..••.• ..

.5 volt Each cable . . . . . . , . • . . • .• .4 volt Starter solenoid . . • . . . . . . . . . 1 volt Each connection. . . . . . . . . .. .0 volt Ground circuit, . . • . . • . . . •. ,5 volt Test temperature . . . . . . . . . 60· to 80· F. (15.6-

to 26.7° C)

Te.t 1 - Determining Cranking Voltage 1.

BAnERY

"''' ,;l!-J)

Voltmeter should read at least 9.6 volts, If above the minimum. cootiDue testing.

H below minimum, replace or recharge

,..--HEGATlVE UAO

~ -.....-)

BATTERIES

STAltUR

POSITIVE UAD

GRCI.IIO-

"'''

.JL

Figure 3 - Insulated Circuit Test drop in the entire insulated circuit. H drop is .5 volt or less, perform Test 4. If drop is over .5 volt, proceed to Test 3 below.

(ground).

Crank engine and reoordvoltagereading.

_~TI€TER TESHR

"-'-.

Attach positive voltmeter lead to positive battery terminal and negative voltmeter lead to negative battery terminal

8 • SATIEIn' T~IAAI. S • S'oIITOt TERPlIIW. 11 • IIITOII TEmIfW.

Test 3 laoiating Insulated Circuit Defects p

battery. Teat 2 - Insulated Circuit Teat

These tv.o tests will isolate the defect ..in the insulated circuit which showed up in Test 2.

This test wUl reveal any excessive resistance In the circuit from the battery through the starter solenoid.

Refer to Figure 3. Move positive voltmeter lead to the M terminal on starter. Negative voltmeter lead remains on battery.

Crank mgine and record voltage readIng.

Subtract this reading from the figure recorded in Test 1. This is the voltage

CABLE. BATTERY TO SOLENOID TERMINAL. Connect positive voltmeter lead to positive battery post. Connect negative voltmeter lead to B terminal on solenoid. Crank engine. If voltage drop is .4 volt or less. proceed to step 2. If drop is over .4 volt. replace the cable.

SOLENOID. Connect positive voltmeter lead to B terminal on solenoid. Connect negative voltmeter lead to M terminal on solenoid. Crank engine. If drop is over .1 volt. repair or replace solenoid.

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8002-12

Test 4 - Ground Circuit Test

B S

Excessive resistance in the ground circuit can cause sluggish cranking action or failure to crank and can also seriously interfere with the operation of the charging system. 1.

Refer to Figure 4. Connect the voltmeter negative lead to negative battery post. Connect the voltmeter positive lead to the grounded end of the ground cable.

a a a

BATTERY TERHIHAL SWITCH lERHl1W.. MOTOR TERMINAL

TESTER Ufm

NEIi'oTIVE LEAO

BATTERY

Crank engine. If voltage drop is over. 5 volt, clean and tighten the ground cable connections. Recheck the voltage drop, if still over .5 volt, replace the ground cable.

STARTER POSITIYE LEAD

Figure 4 - Ground Circuit Test

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Section

8003 WIRING DIAGRAMS

J I Case A Te nneco Company

E. Div. 9-66015

February 1976

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8003-2 The information on this page applies only to Figure 1.

WIRING COLOR KEY 1. 2, 3,

4. 5. 6,

Red Yellow-White Yellow Purple Light Green

7. 8.

Yellow-Black Purple-Red

13. 14.

9. Pink 10. Gray 11. Orange 12. Black

WhIte

15.

16. 17. 18.

Red-Black White-Orange Yellow-lted Purple-White Light Blue Blue

COMPONENTS A. B. C. D, E. F. G. H.

AA. BB. CC. DD. EE. FF. GO. HH. II. JJ. KK. LL. MM. NN. 00, PP. QQ.

RR S8, TT. UU. VV. WW. XX. YY. Z Z, AAA. BBB, CCC.

illumination Light R.H. Turn Signal, Refer to Figure 4 or 5 Not Used Hyd. Oil Filter Warning Light Air Cleaner Warning Light Alt. Warning Light Eng. Oil Pressure Warning Light L.H. Turn Signal. Refer to Figure 4 or 5

J. K. L.

M. N. O.

P. Q.

Trans. Oil Temp. Voltmeter Eng. Water Temp. Fuel Level Gauge Battery Turn Signal Switch, Refer to Figure 4 or 5 Turn Signal and 4 Way Flasher, Refer to Figure 4 or 5 Horn Button, Refer to Section 8015 Connects to Cluster

R. S,

T. U. V.

w. X. Y.

Key Switch Connects to Key Switch Starter Button Clutch CUtout Control Light Switch Flood Light Switch Flasher Switch Rotating Beacon Air Filter and Hydraulic Oil Filter Restriction Warning Light Check Switch

Flood Light, Turn Signal & Brake Light 15 Amp Circuit Breaker, Refer to Figure 4 or 5 Clutch CUtout and Return-to-Dig 10 Amp Circuit Breaker Backup Alarm & Lights 15 Amp Circuit Breaker, Refer to Figure 4 or 5 & Section 8015 Heater and Defroster 15 Amp Circuit Breaker, Refer to Section 8015 Wipers & Rotating Beacon 15 Amp Circuit Breaker, Refer to Figure 4 or Section 8015 Horn and Rotating Beacon 15 Amp Circuit Breaker, Refer to Section 8015 Relay Powers Circuits Controlled by Circuit Breakers DD, EE, and FF Relay Powers Circuits Controlled by Circuit Breakers AA. BB, and CC Instrument Cluster Return-to-Dig Circuit Diode Neutral Start Switch Trans. Temp. Sender Clutch CUtout Circuit Diode Connects to Trans. Clutch CUtout Solenoid Not Used. Connects Upper and Lower Power Shuttle Harness Together Warning Switch Circuit Diode (Air Filter Restriction Indicator) Warning Switch Circuit Diode (Hydraulic Oil Filter Restriction Indicator) Brake Pedal Actuated Clutch Cutout Switch Connects to Light Harness, Refer to Figure 4 or 5 or Section 8015 Floor Mounted Clutch CUtout Switch Engine Oil Pressure Sender Connects From Engine Harness to Main Harness 40 Amp Circuit Breaker Hydraulic on Filter Restriction Indicator Switch Fuel Level Sender Return-to-Dig SwItch Starter Engine Water Temp. Sender

ODD. EEE , FFF.

Air Filter Restriction Indicator Switch Alternator Connects to Bucket Spool Detent

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Section

8004 INSTRUMENT PANEL AND INSTRUMENT CLUSTER

J I Case

A Temeco Comoanv

C. E. Div. 9-66015

'."'nll 'M u.I .... February 1976

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8004-2

TABLE OF CONTENTS Instnl.ment Panel

. . . . . . . . . . . . . . . . . . . . .. . . . . ... . . . . . . . . . . . . . . ..

8004--4

Removal and Ins tallation . • . . . . . . • . • . • . • . • . • • • . . . . . • . . . . • . • . • . . 8004-4 ln8t:nunent Cluster

.. .. . . . . . . ..•. . . . . . . . . . • . . . • . • • • . • . • . . . . . . . . 80G4--4

Removal and Installation ...••• •••• • • • •.•.• • •.•.• • ••• . • • . . . . . • . 8004-4 Replaclng L1ght Bulbs Circuit Board

. . . .••..•• . . • . . . • . • • • . • . • . • . . . . . . . .•.•. 80G4-4

Gauge Removal and Installatton Checking Gauge

.. ..

. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . ~er atlon

8004--4

••..••.•• . . . . . . . . . ... ...•••••. •.• 8004--4

. . . • . . . . . . . • . • .• . . . • . . . • . • . • • • . • . . . . . 8004-5

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•

8004-3

•

,. I.

COVER

GASKET

•••• ••7.

IDE~IFICAT!ON ST~I~

TACHOMETER

VOLMTER FUEL GAUGE

WATER TEJoIP.

••

12.

OIL TEMP. GAUGE (PMR SKUnLE OHL Y)

ASSEHBLY •• CASE: IlARIU JIG 1I6111'6ULB 10. (NO. 194)

II.

"""

ILlUMINA.TlOl'« LIGHT BIJLB

". ".".

(HO. 168)

BULB SOCKET BOOT (tULIliHATIre

'I.,i;

llGHTS ONU) ACCESS COVER BunCH (USED IN

PLACES OF SWITCHES)

,-,

Figure 1

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8004-4

â&#x20AC;˘ STRUMENT PANEL Removal and In tallation 1.

Disconne t ground cable at b atte ry.

Loosen the top clamp On the connecting sleeve OIl the throttle and shuttle control shafts. love clamp to expose r oll pin and drive out pin. Heat treated washe rs may be installed D top of shuttle r o connecting sleeve if equipped with power shuttle . Look for washe r(s) to fallout when th insb"Ument panel 1s r emoved.

harness plug between thumb and first finger; squeeze plug and pull frorr: cluster. 4.

Re move the four inst r u ment clu st r retaining sc r ews and re move cluster.

D sconnect h arne ss plugs from switChes. Tag h arness plugs as r equtr d to as sure pr per installation.

Re move fuel shutoff lmob. I erno e -able housing retaining nut and remove c a. Ie from instrument panel.

Re mO'Ve the inst rument panel mounting screws and steering col n clamp . and rem ove instrument panel.

Re verse the preceeding s teps to inst al the instrument panel.

NOT :

Jrnove access covers n top of instrument panel. Disconneot t achomet er c able; push sprIng retainIng clip toward I.r strument clus ter and pull cable ut. Grip top a.'1d bottom of cluster

INSTRUMENT CLUSTER Remov I and InstaUation top of in-

Remove an access cove r instr ument panel.

Disconnect tachomete r cab e: push spring clip toward instrument cluster and pu I cable out.

Grip socket of bul b to be rep ace and turn it counterclockwise t o emov soc ket.

Grip top and bottom of cluster h arness p ug between thu mb and fi r s t finger ;

Pull bulb from s ock t.

Remove

8e ess cove rs 0

~trument

pan 1.

To repl ace a bulb: n top of th

squeeze plug and pull from cluster.

Circuit Board 4.

Re move luster mounting screws and remove cluster.

Normally, the circuit board will no he

a s ou rce of trOUble. However, if the 5.

Reverse steps 1 through 4 to install the instrument cluste r.

stru -

me nt cluster i s mishandled, damage ould occur. If the circuit board requires r epl ace m e nt, the cluster case asse mbly must be rep laced.

Rep' cing Light Bulbs Each ins rument cluster contains s ix

Gauge Removal and Installation

warning light bulbs (No. 194) and three i -

lumination bulbs (No. 168). The bulbs are r stalled in removable sockets .

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Re move iost-rument cluster as instructed on thi s page.

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â&#x20AC;˘

8004-6 2.

Remove the four leDS retaining acr8W8

and remove lens. 3,

IiI'1

Cilmmeter and cheekior con-

plug and

Remove the screws that bold gauge in place and pull gauge straight out of cue. Dopendlng on which gauge ta being Temoved, it may be neceSSa.ry to remove the gauge next to It.

sendin&

unit terminal end.

II wire Is good. remove 1nBtrument cluster as tnatructed in thls section and replace the gauge.

Before replacing tbegauge.checkthe eJ.rcuit board to be sure it La not at

Reverse steps 1 through 3 for gauge tnstalIation.

Checking Gauge Operation 1.

Use

tinuity between the cluster harness

If a gauge fails to operate: a,

Disconnect wire from the gauge sending unit.

fault.

If gauge operatiOD Is erratic pected of being incorrect:

Ol'

is sus-

Cleek for loose or corroded conneotion at the sending unit.

Ground the disconnected Wire and turn key switch on. If needle moves to lull scale the seDding unit Is at fault and must be replaced. If the ne&dle fails to move, the wire to the ,auge or the gauge itself Ls at fault.

Check for the posslblUty of the wire or harness being groundied (l!Ibort circuited) part of the time. If

steps a and b do not correct the

problem. replace the gauge.

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Section

8005 BATTERY

J I Case

A Tenneco Comoany

C, E. O1v. 9- 6601 5 ..... 10 .. 11.1..&.

F ebruary 1976

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8005-2

TABLE OF CONTENTS Specifications . . . . . . . . . . . . . . . . . . . . . . . . Care and Maintenance Nonsp1ll Battery Caps

8005-3

. .. . . . . . . . . . . .. . . . . . . . . . . .

......... .. ..

8005-4

. • . . . • . ••••.•...• .• . • .. •.• . •.•.• . . . • . . . . 8005-5

Battery Tests . . . . . . . . . . . . . . • . • . . . . • . • . . . . . • . . . . . . . . • . . . . . . . . . . 8005- 5 Specific Gravity Check . . . . . • . . . . . . . . . . • . • . . . . . . . . . . . . . . . . . . . . . 8005-5 Capacity (Load) Test . . . . . . . . . . •• . . .. . • .••.••• . . . . . • . . . • . . . . . . 8005-6 IndIvidual Battery Cell Test . . . . . . . . . . . . . . . . . . . •.•.• . • . •.•. • . . . . 8005-7 Soft Top Battery or Exposed Cell Connectors . . . . . • . . . • . • . . . • . . . . . . 8005-7 Hard Top Battery . . . . . . . . . . . . . . . . . . . . . . . . . • . • . • . • . • . . . . . . 8005-8 Battery Charging

. . . . . . . . . . . . . . • . . . . • • . . . . • • •.•.••. • .•. •••..... 8005- 9

Activating Dry Charged Batteries

. . . . . . • . • .•. • . • • •.• ••.• . • . •.. . . . . . 8005-10

Battery Charging Guide . . . . . . • . . . ..• • . . . • • . . • . • . . . . . . . . . . . . • . . . . 8005-10 Battery Check Sheet

. . • . . . • . . . . . . • . •••••.•• .•• ..• . •.• . • . . . •.. .. 8005-11

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•

8005-3

SPECIFICATIONS

. .. .. . . . .

Number and sue

. . • ..

'!\vo 12 volt bo.ttodee oooneoted In

serIes, negative ground. Group size 30H,

SAE No. 9H9A•

300 amps at D° F. (-17' C) 10 secOIld voltage -9.2 V 'IIin6: 5 minutes to 1.0 volt per cell 90 nccmd diesel ratina: . • • • • • . • • • • • • • • • •• 575 amp draw for 90 secoods at 0" F. (-17' c.) to 1 volt per cell Capacity (load) test draw .... . .. . • . • • • . • . . • . . . . . . .. 200 amps Full charge 8peciflC gravity 1.260 :0: .005 (orlgiDal equipment or . .. ClUJ. replacement batteriu only). Plates per cell . . . . . . . . . . . . . . . ... . . . . . . . . , • • • • • . . • • . . . • . • . . • • • • 17 CapacIty

. _ .... . .....

. . .. .. . .

Slow charglng rate

... , .••

We.lgbt 'NUb elcouolyte

(

C AUTION 11 (l1

I \

h ..

"".' 'H '1

I ,I g'll~ ..:

0:'

tt '"

•

8 amps

66.6 pounds (30 kg)

'. _ "

! •

C AUTION . :";<'1 • ,I \, It'·1 \,' 1 .' ,1. I t ! t

~'l\\"'(,

! . ' ~ • • • • • • • . • . . . . . . . . . . . . . . . . ..

. . . • . . . . . . . . . •..•.••. •. , . . . . . .

- t

\,";":- ~ • ~. _'.

•

...

- • l~

•

.. •

•

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• 8005-4

•

CARE AND MAINTENANCE A battery can be considered a perIshable ltem, therefore it Is only natural to assume that proper care and maintenance will aid in obtaining maximum service life.

of time indicates_an undercharged battery. Poor cable connectloos or a too low voltage regulator setting may be the cause.

A check sheet wlll be found on the last page for use in battery inspections. Extra copIes can be easily reproduced on any o((Ice dupl1cator.

Cleaning

HOYt

Electrolyte Level The electrolyte level should be checked every .50 bours of operation or weekly. Extensive use in hot weather wtll require more frequent checks because of a more rapid water-"1088. If the electrolyte level Is low. add colorless, odorless drlnktngwater to each cell until the fluid level rises to the split ring at ibe bottom of the cell opening. Over· filling serves no . useful purpose and wUl result in poor performance. short Ufe and excessive corrosion around the b~Ty.

The battery should be inspectedperiodically for dirt and corrosicn. and damage. Dirt, combined wIth electrolyte or moIsture on the top of the battery usually results in a continuous battery discharge because this foreign material produces a path for battery current to follow. Due to the higher voltage involved, 12-volt batteries are more susceptible to energy losses of this nature than 6 volt batterIes. The battery and cable 'terminals can be cleaned using one of the following methods:

'Use Cue Battery Saver, part DUlUber M20376. II..\cordiDg to instructions on container. This 1s a spray and wipe cleaner that requiTes no water. It ~so prevents further corrosion.

Use soda or ammonia, and water and fiush battery with clear water. H Case Battery Saver 1s not available, install corrosIon retarding washers under the battery cable terminals. Tbese washers are available from parts supply houses and most discount stores.

NOT.: Add water only. not electrolyte. when serviCing the battery.

Maintain the electrolyte level above the plates at all times to prevent permanent damage which will result in reduced performance and service life.

Water Usage Excessive water usage indicates bigb battery temperature and/ or high voltage regulator setting.

No apprecIable water use over a perIod

It Is -recommended that the battery be removed and the battery carrIer cleaned at the same time.

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• 8005-5

NONSPIU BATTERY CAPS equipped

and valve to become plugged When tW8 hap-

with batterIes that have nonspUl caps. These prevent personal Injury and mach1De damage from 11J11lled battery fluid U the machine

The uonspllJ CIP contains a lead/soft

peDJ!l. intern&! battery presSIlI'e great enough to splU the battery case can occur. Therefore, check for plugged vent nole when checklng battery Quld level. Hold cap upside dov"n if uq:llugg1ng the external vellt hole. Shake cap to make sure valve moves freely (ratUes in

rubber stem valve. lNhen the cap Is upside down, the weight of the lead portion holds the rubber stem against the external vent hole to preftlDt 10ea of battery fluid.

aide the cap Shake cap v1gorously to remove water from inside of cap.

Mo.t

mach lnel!l are

factory

111 accidentally upset.

cap) J1 valve Is stuck. rinse oap in water to tree the valve and remOTe duat, etc. from m-

Whenever a cap 18 removed, check CODdItion of the rubber gaakel If the (uket Is damaged to the extent that It wtll not provide II. leakproof seal or the gasket Is missina'. the cap must be replaced. MlHlling or broken nonspUl Capll MUST be replaced with another nonaplll cap. DO NOT use standard cape to replace nOMPill cape.

Figure 1 - NonspUl Battery Cap It Is poulble for the external vent bole

When inatalilng a replacement battery and the battery being removed Is equipped with nonsplll caps, the repl~ :~ !l.t battery MUST be equipped with nonsp111 oop •• U.. eapslrom original battery.

BATTERY TESTS

Specific Gravrty Check

_ _

A hydrometer ia used to ohaok the specitic lI'av1ty (weight) of the battery electrolyte. The specific gravity of the electrolyte indicates the approximate state of chal'&e of the battery. Hydrometers are calibrated to give the true readlngwhen the electrtJytetemperature III 80' F. (26.7" C) . 'Therefore, to obtain - - • ....oonec1....sectflc... runtY read~ tem perature of the electrolyte mUllt be known. Some hydrometera conhJn a thermometer whlle others do not A separate thermometer Is required to cbeck; eleotrolyte temperature if the hydrometer 18 not 80 equipped.

NOTS:: If water must be added to check. speol1lc gravity. fast charge battery for 30 minutes or false readinp will be obtaiDed.

Remove electrolyte from one cell with the byclrometeT. Observe and Tecord tbe hydrometer reading.

Note the electrolyte temperature. Refer subatract-four - (.a04) apeolf1c gravity points for eachlO· above or below 80' F. (26.7' C). The corrected readina: will be a true indic.t10n of cell condlt1on.

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100" 75% 60% 25%

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SpecifiC gravity. Electrolyte 80* P. (26. r C) freezes approx.

State of

11 all cella read between 1.200 and 1.260 and the varlatioo bet\Yeen the b.1gb and low cell 18 30 gravity points or more, fully oha.rge battery and recheck specUlO gravity. U the varlatiCD. Is still 30 gravity points or more after charging. the battery is defective and must be replaced.

Dlscbarll'ed

1.260 1.230 1.200 1.170 1.110

-75" F. (-59"' C) -38* F. (-39" C) -17" F. (-28" C) 1501.5

r F. (-17" C) 19" F: (-7.TC)

Figure" - Specl.Ac Gravity Table

Figure 2 - Cbeck1Jlg Specific Gravity

Repeat steps 1 and 2 for the remaining cells. ~_"TU"'. ~

1.. "il=:~ 1501 ..

140 130

," 110 100

~ f~l::t

The capacity of a battery is the battery's ability to furnish current and maintain a mInImum necessary voltage. U a battery passes the capacity Test, it1sln satisfactory OODdiUOIl. It may, however, need charg1n& to bring it to peak performance.

Test Conditions

"" GAAVITY"""'" POINTS

FROM HII)(H(I[It

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Figure S _ Temperature Compensation

Interpretation Of Hydrometer Readings 1.

The state of charge can be determined by oomparing readings to the Spec1fic Gravity Table.

U all ceUa read between 1.200 and 1.260 and the variation between the high and low oell 18 le88 than 30 gravity po1nts, the battery Is good. It may be necessary to charge the battery prior to putting the battery 1n service.

The test should not be performed if the electrolyte temperature is below SO" F. (28.'" C) or If the battery's state of charge 1s los_ than 75%, Charge the battery as required to meet test conditions.

Test Procedure 1.

Refer to Ftp.re 6. Turn the control knob of the tester to the OFF poslUCD..

2._ Turn the voltmeter selector SWitch to 8 volta for • 6 'YOlt battery. or to 16 volta for a. 12 volt battery. 3.

••

Connect the -positive test leads to the posttive hattery post and the negative test leads to the "negative battery post. Turn the oClltrol knob clockwise unW the:

ammeter reading 1s exactly three tlm. . the ampere hour rating of the battery. (Example: 180 amperes for a 60 AH battery.) If the ampere hour ratln&' I_not known, adjust oClltrol knob unW ammeter

Indtcates 200 amperes.

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8005-7

Soft Top 8attefy or Exposed Cell Connectors

'-'I

Refer to FJaure S. Turn voltmeter selector switch to 8 volta ror a 6 vcit battery or to 16 volts for • 12 volt :battery. Ccmneot a battery oharrer ilnd voltmeter

to the battery. C<:w1ect positive leads to the ~tt1ve battery post aDd negative leads to the negaUve battery post. Figure 5 - Capacity (Load) Test Hookup

3. ~

If the battery under test has been designed for WI., in hlgb temperature climates, adjust the control knob unto the ammeter Indicates exacUy two and a balf times the ampere boor rating of the battery. (Exampl",: 150 amperea for .. 60

3 m1D.UtH.

4..

Maintain load for Meen soooods. note voltmeter reading, tIwm turn controlknob to the OFF position,

Adjust charging level to the bigbest rate

po8sible without exceeding 75 amperes a 6 volt battery or 40 amperes for a 12 volt battery. ro~

AH battery.)

Turn charger CD and tum charger time switch paat 3 minute. and then back to

After 8 minut•• , wlMm time switch has

returned. to elow charge, reeet switch to fast obarge and observe the voltmeter.

If the voltmeter indicated 4.8 volts or more for a e volt bdter}'. or 9.6 volts or more for a 12 volt battery. the battery baa good output capacity. Check specific gravity as instructed on pap SOH-D, .am If necessary. charge battery before ' -placing back tn service.

U rood!"g ia beyond green band or

exceeds 7.75 volts lor a 6 volt battery or 15.5 volts for .. 12 volt battery, the battery 1a sulfated or worn out lind the battery ahould be replaced.

If voltmeter re&d1.ng was Ieee than 4.8 volts for a 6 volt battery or 9.6 volta for a 12 volt battery. oc:mduct

11 'read!. 18 within the greeo baD:l or -lees tb8D 7.76 volta for & 6 volt battery or 15.5 volts for a 12 volt battery. proceed with step 6.

the Indiv1dual Battery Cell Teet to determtne if batteJ:y ta discharged

.or defective.

With ohArgex operating OIl fast oharge, set voltmeter SWitch to 4 volta. Observing polarity, quickly meaaure cell volt-

Individual Battery Cell Teat

age acroas each cell with voltmeter.

The lollO'Ning testa should be performed batteries that fail the Capacity (Load) TNt.

~y CD

U the oell reading8 vart by more than .1 volt. battery has defective cell(s).

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8005-8

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FIgure 6 - Cell Test, Soft Top Batteries and Exposed Cell Connectors b.

II the cell readings are withfn .1 volt and the total voltage Is within the IJ.nrlts specified in step 5. the battery is discharged and is in need of recharging.

Place positive probe; in cell No. 3 and negative probe in cell No, 4. Record the exact reading.

Place positive probe in cell No. 4 and negative probe in cell No.5. Record the exact reading.

Place positive probe in cell No. 5 and negative pr.obe in cell No.6. Record the exact reading.

Hard Top Battery This test is performed usingtbe cadmium probes and a suitable battery-starter tester. Figure 8. Connect the voltmeter leads to the terminals in the end of the handle, observing polarIty color code. Set voltmeter switch to 4 volts and remove the 1ill.er vent caps from the battery. 1.

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Place pOSitive probe in cell No. 1 and negative probe in cell No.2, Figure 7. Record exact reading. Place positive probe in cell No. 2 and negative probe in cell No.3. Record the exact reading. H testing a 6-volt battery. proceed to step 6.

C) e,1I

C) 6

C) II

Figure 7 - Battery cell Sequence

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8005-9

reading to the reading obtained in step 6.

Place the positive prod on positive battery post and negative probe in cell No. 1. Record the exact reading. Place pOSitive probe in cell No, 6 (No. 3 for 6 volt battery) and negative procf. on negative battery post. H the voltmeter reads to the right of zero. add t.h1s

If the voltmeter reads to the left of zero,

reverse the probes and subtract this reading from the one obtained in step 6.

If the cells vary over .1 volt. the battery sbould be replaced. -

TERI'I!NA.L

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CE"

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Flgure.8 - cadmium Probes

BATTERY CHARGING "Before charging a battery. check and adjust the electrolyte level as required. Refer

to Electrolyte Level, page 8005-5. Charging rates in the 3-50 ampere range are usually acceptable. It Is d1ff1cult'to specify a definite charging rate or time because of (1) ampere hour ratings vary; (2) temperature of the electrolyte; (3) state err charge at the start of the charge period; and (~) the age and cond1tioo of the ba.ttery. Refer to chart on page 8014-10 for charging rates and times for fully discharged battery. It may be said that any battery may be c1larged at any rate in amperes us lcmg as

the electrolyte does not boil over as a result of violent gassing or as long as the elec-

trolyte temperature does not exceed 125Âˇ F. (5r C) . If the electrolyte bolls over or the temperature exceeds 1250 F. (5r Cit the cbarging rate must be reducedortemporarlly balted to avoid damage to the battery. N01't: For the most satisfactory charging. the lower ampere charging rates are recommended.

The battery is fully cbarged wben over a two boor period at a low charging rate, all cells are gasSing freely (not boiling over) and no change in specific gravity occurs. The full charged .specific gravity is approximately 1.260. Fill each cell until the electrolyte is eveo with the spltt ring at the bottom of the cell opening.

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•

8005-10

•

ACTIVATING DRY CHARGED BATTERIES NOTa: Also refer to NonspUl Battery Caps on page 8005-5.

check the terminal voltage. U the voltage is less than 5 or 10 volts, depending OIl rated voltage, the battery is defective and should be replaced.

Dry charged batteries are activated by ruUng each cell with electrolyte (a soluUoo of sulfuric acld and water) with a specific gravity of 1.260. Fill each cell until the electrolyte is even with split ring at the bottom oi the cell opening. Set the battery aside for a few mlnutes, then check the electrolyte level. If the electrolyte Is low, add additional electrolyte, not water. Adding water when activating a dry charged battery may result in poor performance and a short service Hfe. Prior to putting the battery into service, complete tbe following tests to assure good battery performance. 1.

Check the specifiC gravity, page 8005-5. If the specific gravity shows more than a 30 gravity point drop or one or more cells gas violently after adding electrolyte. the battery shouldbefullycharged before being put into service.

For the best performance in cold weather (below 32" F. (0· C) or tithe electrolyte is not at 60· F. (16 0 C) or above at time of activation, warm the battery by charging.

Five minutes after adding electrolyte,

After electrolyte bas been added to a dry charged battery it should be maintained in the same manner as any other battery.

BATTERY CHARGING GUIDE (Fully Discharged 6 and 12 Volt Batteries) Ampere Hour Rating 5 Amperes 50 or less

10 hours

Recommended Rate and Time 10 Amperes 20 Amperes 30 Amperes 40 Amperes SO Amperes 5 hours

2-1/2 hours 2 hou'O's

Above 50

15 hours

7-1/2bours 3-1/4hours 2-1/2hours 2 hours

to 100

20bours

10bours

Shours

3 hours

2-1/2 hours 2 hours

Above 100 to 150

30 hours

15 hours

7-1/2 hours 5 hours

3-1/2hours 3 hours

20bours

10 hours

1-1/2 hours

Above 75

Above 15 ' HOTS ••

6-1/2 hours 5 hours

4 hours

Amperes indicate initial rtlte {or constant voltage taper Tate charger.

NOT• •I Reduce or temporarily halt charging rate if electrolyte .t emperature exceeds

125*

(5r C) or violent gassing (boUing over) occurs.

NOT. ~ "For the most sattsfactory charging, the lower ampere charging rates are

recommended.

Figure 9 _ Battery Charging Guide

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Section

8006 STARTER AND STARTER SOLENOID

J I Case A Tenneco

Compan~

C, E. Div. 9- 66015 ......... ON u.~ .

February ]976

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8006-2

TABLE OF CONTENTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8006- 3 Specifications . . . • . • . . . • . . . . • . • . • . · . . . . . . . . . . . . . . . . . . . . . . . . 8006- 3 Lubrication . . . . . . • . . . . . . . . . • • • . •. · . . . . . . . . . . . . . . . . . . . . . . . . 8006-3 No-Load Test . . . . . . . . . . . . . . • , •.•. · . . . . . . . . . . . . . . . . . . . . . . . 8006-3 Pre-Test Checks ... ' , ..•.•.•.•• · . . . . . . . . . . . . . . . . . . . . . . 8006-3 Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8006-3 Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8006-3

starter

.. .. .... .

Servicing the Starter . . . . . . • . • . • . • . • . . . . . • . . . . . . . . . . . . • . • . . . . . 8006-5 Removal . . . . • . . • • • • • • • • • . . • • • • • . . • . . • • • . • • • . . • • • • . . . . . 8006-5

Disassembly . . . . •.• .•.•.. , .. . .• , . . . . . , ... , ••... .. ••.... 8006-5 Inspection .. . . . . • • • • •.•. •.. . . . • • . . • . . . . . . . . . . • . . . . . . . . . 8006-5

..... . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . . . . . . . . . · . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .

. . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8006-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8006-7 Assembly

Armature Tests Field Coil Tests

.... . . . . . .. .. .. . .. .. . . . .. .

· . . . . . . . . .. . . . . . . . . . .. . .. . . . . . . . .. . Starter Solenoid . . . . · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Tests . . . . . . .. . . . . . . .. . . . . . . . . .. . . . . . .. . . . . . Pinion Clearance

6006-7 8006-8 8006-8 8006- 9 8006-9 8006- 9

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•

8006.3

STARTER Specification.

Case -part number • . •••••••••••• .. •.• •...•.••• ••.••••••••••••••• R29870 De1co-Remy part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1109149

No-Load test at 80' F. (26.7" C) Volta • . . . . . . . . . . . . . • . . • . • . . . . • • • • •••••••••••••••••....• ....• 9 Amperage draw, blcluding aoltmoid

. . . •.•, •• .. ••••.•. .. . . . . • . . . . .. 40-140

Revolutions per minute . . . . . . . . . . . . . • . • • • • . . . • . . . . • • . . . . . • 8000-13000 Rotation viewed from drive end • . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . clockwtae Pinioll olearance .....•••••••••••••.•..•••••.•.. 010"-. 140" (0.254-0. 356 mm)

U.ric.tion ht8rval . . . . . . . .. , •...•••.••. ... . . . . . .. . . . . • . • Wbm starteJ' is diaassembled LUbr1cant • . . . . . . . . . • • • . . • . .. . . . . . . . . . . . . • . . . . . • • . . . . . . . Light f!Ilgine oil

No-Load Test

Make sure carbon pUc Is off and oonnect carbon pile to battery.

Close the switch and adjust the carbon pUe untU tbe voltmeter lndlcates 9 TOlls. Observe the taemmeter and ammeter and

Pre-Test Checks 1.

With the starter removed from the engine, check the pinion for freedom of operatJon by turning tt orr. the armature

f'8OOrd the readtnp.

shalt.

Check the armature for free-rotaUon by prying against the pinJon with a screwdriver. If the armature does l10t rotate freely, dlBusemble the starter and repair u required before performing the

NOTa: Do Dot operate the starter more than 30 Booonds at a UmewttboutpBUSin&, to allow it to 0001 toratleasttw minutes. 6.

Opeo the switch and turn aU the carlxJn pUe.

No-Load Telt. AKI1EtER

Test Equipment IlATTU,y

This test ean be perfOrmed using a Sun EJ.ectrlo Battery/ Starter Teeter or equivalent. or by using .individual test equjpmeot u illustra.ted In Figure 1. The ammeter must be capable of JndlcllUn, 300 amperes. A tachometer to measure armature rpm and • switch (knife type) are also required.

VOL n1ETElI

CARSON PILE

Test Procedure 1.

Connect the starter and anuneter .In serlea with a fully oharged 12 volt battery as sbown .kl Figure 1.

Connect the voltmeter to the solenoid M terminal and the starter frune.

Connect the switch to the B and S terminal, on the solenoid.

R,," I HO I CATOII

F1gu.re 1 - No-Load Test Hookup. DeJoo-Remy

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INTERPRETING RESULTS OF TEST

Failure to operate and no current draw indicates:

Rated current draw and no-load speed indicates normal condition of the cranking motor.

Open field circuit. This can be checked after disassembly by inspecting internal connections and testing circuit with a test lamp.

Open armature coilS. Inspect the commutator for badly burned bars after disassembly.

Broken brush springs, worn brushes, high insulation between the commutator bars or other causes which would prevent good contact between the brushes and commutator .

Low _free speed and high current draw

•

$006-4

indicates:

Too much fricUon--tight. dirty. or worn bearings. bent armature shaft or lOOS8 p>le shoes allowing armature to drag.

Shorted armature. This can be further checked on a growler after disassembly.

Grounded armature or fields. Check ~r after disassembly.

Low no-load speed and low current draw

indicates: a.

Failure to operate with high current draw indicates:

A direct ground in the field terminal or field windings.

"Frozen" bearings (this should have been determined by turnlngthe armature by hand),

•

- '"' ~-

High tree speed and high current draw Indicates shorted fields. If shorted fields are suspected. replace the field coil assembly and check for improved perform&nce.

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High internal resistance due to poor connections. damaged leads, dirty commutator and causes listed under No.4.

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8006-5

Servicing the Starter Removal 1.

Disconnect battery ground cable at battery.

Disoonnect wiring from starter solenoid.

Remove the three starter mOWlttng cap

00 NOT clean the armature, fields or starter drive in degreasing tank, or with greage dIssolving solvents. BRUSHES AND BRUSH HOLDERS

If brush wear is more than half when compared to a new brush, the brushes should be replaced.

Brush holders should be clean and the brushes must not bind in the holders.

Check brush spring tension to make sure the springs hold the brushes firmly against the commutator. If springs are distorted or discolored they should be replaced.

screws and lockwaBhers, Remove start-

er. Refer to Figure 2 and proceed with disassembly.

Disassembly 1.

Prior to disassembly, checkpinlon clearance as instructed on page 8006-8.

Disconnect the field coll connector from the solenoid M terminal.

Remove the tbru bolts. Then remove the end plate and field frame from armature.

Test armatureag instructed under Armature Tests.

Remove the solenoid and lever pivot bolt from drive housing.

Remove the center bearing plate retaining screw and remove armature from drive housing. Then remove thrust wash-

Place armature.in a lathe and turn daVID commutator until all indications of wear are removed.

Undercut insulation between commutator bars 1/32" wide and 1/32" deep. Use 00 sandpaper to remove any burrs from oommutator.

ARMATURE

ar from armature shaft.

Remove starter drive retainer and snap ring.

FIELD COILS

Place a hollow drivingtooJon retainer and drive retainer toward armature to expose snap ring.

Remove snap ring and starter drive

BUSHINGS

Check field coils as instructed under Field Coil Tests.

retainer from armature sbaft.

C. 7.

Remove starter drive and center bearing plate from armature sbalt.

Remove brush holder pins. disconnect brush leads and remove brush mlders and springs.

Assembly 1.

Lubricate bushing in commutator end frame. drive bousing and center bearIng plate.

Place center bearing plate, large thrust washer and starter drive on armature

Inspection

AU parts except the starter drive should be cleaned using mineral spirits and a brush, Use a clean. dry cloth and wIpe the starter drive.

Inspect bushing in center bearing plate. commutator end frame and drive housing for wear. If bushing is to be replaced. soak bushing in 30 weight oil before installation.

,hail

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8006~6

loom I. 2.

T~RU

BOLT

11. lMSlIlATEO UU$H HOlDER

CCHIUTATOR £ND PLAT<

12. BRUSH (4) 13. BRUSH SCREII 14. I'mDR TfRHIItAL CAP SCR£'o/

BUSHING

•. 5. 6.

THRUST WASHER P1.lIG Oil WICI(

15. SCREW

PIVOT PIli ( 2)

17. flELO

BRUS~

16. INSUlATOR

POtJER 5RACKEi (2)

BRUSH SPRING 10. GROUNDED BRUSH

HOLDER

CON~ECTOR

19. FIELD FAAHE 19. FIELD COIL

20. POLE SHOE (4)

Figure 2

21. POI.E SHOE SCREW (a)

21. APJ¥. TURE 23. BEARING PLATE RETAIIIIIIG SCREW 24. CEnTER BEARING PLATE 25. STARTER ORIVE 26. STARTER OR!YE RETAINER 27. SNAP Rillii

28. LOCATING PIli 29 . DRIVE HOUSING

lO. SELF·LOC~IN5 NUT 31. LEVER PIVOT BOLT 32. SHin LEVER 33. GASKET ~. RCl.L PIli

35. 36. 37. 3B.

PLUNGER

PLUNGER SPRING

STARTER SOlEIiGIG LOCK WASHER

39. SCREW

EXploded View of Starter

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8006- 7

Place the starter drive retaine r on the armature shaft with the cupped su rface !acing the snap ring.

Place snap rl.ng on end of armature shaft. Place a pIece of ~'OOd over snap ring and force the snap ring O:l.to the shaft with a light hammer blow. T h en slide snap ring down Into groove.

'Co fOrce tlle

n~t.lner

over the snap r ing.

place a suitable wasber o.er snap ring and squeeze retainer and wasbertogether with plIers. 6.

Re move wuher and install thrustwasber on armature shaft.

.Install armll.ture 111 drive m using and reinstall shift lever and solenoid. Install center bearing plate retaining screw.

Assemble field frame assembly to drive lDusing usingcareoot to damage brusbes .

Position commutator end frame on field

Figure 3 - Armature Ground Test

Armature Short Test 1.

Have armature in same position as pre'l\1m on power. Figure 4.

vious t eat.

frame and Instal! thru bolts . TlgbtE!l thru bolts securel)..

Installation 1.

Position starter against flywheel housing and secure In place witb Cllpscrews.

Connect wiring to starter solenoid.

Connect ground Cable to battery.

, ' --

Armature Tests

680378

Armatu re Ground Test 1.

Place armature !n growler of tester. Turn on fOwer, Figure 3,

-- --

Figure 4 - Armature Short Test 2.

Using s t eel bl ade prov1ded with test er , hold the blade parallel wlth and touc~ ing the armature core segment.

Slowly rotate the armature one o r more r evolut ions. If the armature Is shorted, the steel blade will vibrate.

Touch one test probe to armature core, the other probe to commutator. If test

lamp glows, the armature winding or commutator is grounded.

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•

8006-8

Armature Coil Balance Test 1.

Inspect parts carefully after disassembly.

Have armature in growler and turn on power. Figure 5.

Ii clearance is excessive after assembly. improper assembly is the probable cause.

To check pinion clearance: 1.

Disconnect the motor field coU oonnector from the solenoid M terminal and INSULATE IT CAREruLLY.

Connect a battery of the same voltage as the solenoid from the solenoid switch terminal to the solenoId frame. Figure 8.

08''"' Figure 5 - Armature Coil Balance 2.

•

Follow directions provided with tester and test the commutator bars for abnormal readings which will indicate a short. open. or poor connection. Asatisfactory commutator will give uniform readings.

S(UII)IO

•, •

Field Coil Test., Field Coil Ground Test 1.

Disconnect field 00 11 grounctoonnectlons.

Connect a 12 volt battery and a test lamp to the He ld connector and field frame. If the test lamp lights, a field winding is grounded and the field windIngs must he replaced.

STAJlH~

Figure 6 - Circuit for Checking Pinion Clearance

Field Coil Continuity Test 3. 1.

Connect ' a 12 volt battery and a test la mp to each end of the field winding. If the test lamp does Dot light. a winding is open and the field windings must be replaced.

NOT.: Check pinion clearance quickly to avoid damage to solenoid windings.

Pinion Clearance . Tbe pinion clearance cannot be adjusted but should be checked prior to disassembly and after assembly.

If clearance Is excessive before disaseembly. parts wear is the probable cause.

Temporarily connect a jumper leadfrom the solenoid motor terminal to the solenoId frame. This will shift thepinion into cranking position and it will remain so until the battery is disconnected.

4..

..Push the pinion back towards the commutator end to eliminate slack movement.

Measure the distance between pinion and pinion stop. Figure 7.

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•

8006-9 PRESS 011 ClJTCH AS SHOIIII TO TAJ:f lIP HOV-:J4ENT

''''

....L

-...

•

,- , •

;;;;~- . 140" 'L£ARN<E

F1g.1re 7 - Measuring Pinion Clearance

•

STARTER SOLENOID

Specification. Cue part Dumber' . . . . . . . . . . . . . . . . '• • • • • • • • . . • . • • • • • • • . • • • • • • • • • • • 044891 Del.oo-Remy part number. . . . . .. . . . .• • . • . . . . • . . • • . . . .. . . . . • . . .. . • . •• 1114356 CUrrEillt draw

Hold-in winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5-16,5 amps 010 volts PUll-in winding . . . . ................. . . . . . . . . . . . . . . . 13-15.6 amps 05 volts

<==::>

So ..nold Test.

VOUMl.TY

The solenoid CIW be tested OIl or off the

starter. UthesolenoldremainaoD the starter, dtsc(Umect the field ooU leadfrom the &Cilenoid M terminal and insulate (tape) the field coll lead to prevent the starter from opera.t1ng.

Test No.1 " Hold·ln Winding 1.

Make the tBitt OOllDectloDA

&J!I

shown in

Figure 8. 2.

Close the switcb and adjust the carbon plle untJl voltmeter indicates 10 vults.

Record unmeter reading. turn carbon pUe off and open the switch.

Compare ammeter reading with the teat specifications.

a..

A hlgh reading indicates a sborted or grounded wlndlng.

A low T8Ildlng fndlcates excessive

resl.stance.

Figure 8 - Hold-In Winding Test

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8006-10

•

Test No.2 - Pull-In Winding 1.

Make the test connections as ab:nm in Flgure 9.

Close the switch and adjust the oarbon

pile until the voltmeter indicates 5volta. NOT~ To prevent over heating. do not energize the pull-in wlncUng more than 15 seconds. Current draw w1ll decrease as the winding temperature Inoreases.

Record the ammeter re&d1ng, turn the oarboD. pUe of! IllId ops:! the witch.

Compare ammeter reading with the test speolfloation.

a. b.

A bigh reading indioates a sborted or l(l'Ounded winding.

A low reading indicates excessive reslatance.

F1£Ure 9 - Pull-iII Winding Teat

•

,•

....

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Sec ion 8006A NIPPONDENSO STARTER

Case A Ten n c() Company

C.E. Div. 9-66015 Ap ril 1978

,RIHTID IN U.S.A.

800SA-2

TAB E OF CONTENTS 800 A-3

Specification s

Lu ri .ation . ... ........................ Removing the

tarter ...

I stall ing th e Sta rter

No- Load Test

Disassemb ly ectlon

••

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Fiel d COil Ground Test FO el

Assembl y

o il Open T st , ,

....

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Exploded View of Starter

Starter Sale old Test

•

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8006A -10

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Brushes and Brush Springs ........ Brush I older

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8006A-10 8006A -10 a006A -10 B006A -11 a006A -11 8006A-11 a006A -1 2 800SA- 16

a006A.-17

8006A-3

SPECIFICATIONS Ca e art number ........................................................................... R39341 No-Loa Test at 80" F (26.r C) V It ......................................... . ................. .... .................... . ...... ~ 1 urr nt draw .......................................................... . .... 180 amper s rnaximum Starter drive speed ........................................... ..... ...... 3500 rpm (r/m in) mi nimum

LUBRICATIO Interval ........... . .................... ... .................. When the starter is di sassem bled or each time the engine is r moved for r pairs L ubricant Mo ykote-GN ................. . ............................ Use on sh aft at p.in ion end of star er dr've C se multipurpose grease. see .......... . ................................... Use on bearings, gear , idler gear shaft and springs . Parts Counter Catalog

REMOVING THIE STARTER ,.

Disconnect the gro und ca b le at the battery.

Remove the th ree cap screw that fasten the starter to the flywheel hous ing.

Disconnect the w ires and cab le from the terminals on the starter.

If the mach ine has a power sh u Ie , I sen the clamp that faste ns the b racket t the fill t be for the power shuttle. Then rem ove the br eket.

INSTALLING THE STARTER , . Put the tarler drive end of the starter in the

If the machine has a power shuttle, ut the cl mp over the bracket and tighten th Imp.

flywhee-l housing.

nstall the lOp and bottom ca p screws that fas.ten the starter to the flywheel housing.

Tighten the cap screws tha t fasten he ta er to the flywheel housing.

Put the battery cab le, and bracket if used , on the

Connect the w ires and cable to the term inals o n the starter.

I Ird cap screw and Insta ll the cap screw.

NO-LOAD TEST General I formation

Test Equipment

The No-Load Test is done with the starter removed from the engine.

The No-Load Test can be done using a S in El ectric Battery/Sta rte r Tester or an equal ester, r using separate test equipment as sh W In FI ure 1.

Check to see if you can pull the gear on the tarter drive out of the starter drive housing.

..heck to see if the starter drive can be turned. Pull he gear on the starter d rive o ut of the starter drive housing. T urn t he gear to turn the starter rive and the armature. If t e starter drive can not be turned, disassemble he starter and make repairs as needed. Then d he No- Load Test.

The ammeter must have the capacity to measure at least 300 amperes. A hand held tach om eter and a remote starter switch are al so needed.

800SA -4

No-Load

est Procedure

Check the starter drive speed .using e hand held tac hometer. Make a reco rd of the starter drive speed .

Look at he am me ter and make a record of the ammeter indicat io n.

Release the bu tton n the remo te star er switch . Then turn the carbon pile co ntrol to th e Off posiÂˇ tion .

Connect the starter and am meter to a fully cJ arge 12 sttery as show n in Figure 1.

O"------~lOC. J ---.

Explanation of the No-Load Test Results

1. 1] VOL T BATTERY 2 CA RBON I~Il E ~.

AMME"'"ER

4. VOLT IETE S. REMOTE STARTER SWIT CH

If the current d raw and the starter drive speed were as specified , the starter is g o od .

Low starter d ri ve speed and high curr ent dra w are ind~cat!ons of too much fri cti on aused by:

8 . MOTOR TERMIN AL 9 . BATTERY TERM INAL 10. SWITCH TERM INAL

Fi gu re 1

,~.

e Figu re 1. ,-"onnec t th e voltm eter to the motor termina l an he mo nHng flan ge on the starter. C an ect t e re o te starter switc h to th e battery ar I a nd he switch term inal. Be ur . the carbon pil e IS in the 0 11 position . Connect th ca rbo n p ile to the battery posts. NOTE: Step 5, ste '6 and stap 7 must be done r pidl y . Do no run the starter fo r more than 30 seeon s tone t ime. After the starte r 11as nm for 3 second you must .Ie t the starter cool fo r two mi utes.

:) .

Worn or damaged bearings.

A bent arm atu re shaft.

Loose pole shoes in contac t ture.

A damaged armatu re winding. Disassem b le the starter and check the armature on an armature tester using the manufacturer's in Âˇ structions .

Damaged field coil. See Field C oil ests o n page 8006A-11 .

780425

6. ST ARTER 7. HAND HELD TACHOMETER

,..;

Hold the butto n on the remote starter switch in . Then tll m th ' carc on pile control until the voltmeter shows 11 oils .

ith the arm -

Starter drive does not tu rn and hig h c urrent draw are indicatiJons of: a.

A broken connection at the motor te minaL

Damaged 1ield o il. See page 8006A-11 ,

Damaged bearing(s) .

laid

oi l l

s son

Starter drive does not turn an d the cu rrent draw is zero are ind icatio ns of: a.

An o pen field circuit. D isassem ble the star er and nspect the fi eld co il connections .

A n open armature wi nd ing . Disassemble the starter and chec k tor burn c o utator ba rs . Check the armature on an armat u re tester.

8006A-5

Brush (es) not making good contact with the omm utator bars because of high insulation between the co mm utator bars, broken brush spring(s) or worn brushes .

Low starter drive speed and low current draw are indications of: a.

irty co nnec tions (corrosion) .

b. Damaged wiring.

Dirty commutator bars.

All of the causes in step 4.

High current draw while th e starter drive is turn ing is an indication of a short c i cult I I he fi Id coil. It Is difficult to fi nd a sho cl rcu t in a field coil. Install a new field oil housing assp.mbly. Do the No-Load Test again t hec k f r im provement in the operation of the starter.

800SA-6

DSASSEMBLV 1.

Pu ll back the rubber boot on the motor terminal Loose t e nu on the motor terminal. Then remov he nut. lock was her and cable from the motor te minal.

Figu re 5

Figure 2 2.

L osen and remove the Phillips head screws in the end over.

Use a screwdriver to separate the end 0 erfrOIT: the fiel d frame. Th en remove the end over.

Use a pair of needle nose pli ers t pull the br JS spring away from one of th e br shes onnected to the field coil. Then remove the brush from the brush holder. Use the sam e method 0 remove the other b rush con nected to the fiel c il.

Fi gure 3

Loosen an d rem ove the hex head cap screws that hold the field frame assembly in position . Fi gure 6

Fig ure 4

800BA-7

Use a pair of needle nose pliers to pull the brush spring away from o ne of the brushes in the brush holder. Pul l the brush part way ou t of the brush holder and release the brush spring against the brush . This wi ll hold the brush in position. Use the same method to hold the other brush in the brush holder.

Remove the armature from th e sta rter solenoid housing.

Figure 10

10. Put the starter solenoid housi g in a vise as shown in Figure 11. T hen loosen and rem va thescrews that fasten the starter solenoid housing to the starter drive housing. Figure 7

7. Remove the brush holder from the armat ure.

Fi gure 8

Remove the field fra me assem bly from the arma-

tur .

Figure 9

Figure 11

11 . Remove the starter drive housing trom he s tarter solenoid ho usi ng .

Figure 12

8006A-8 12. Put the starter drlv hous ing on the bench with the gear on the starter drive o n the bench. Push down on the starter drive housing to loosen the starter d rive.

15. Use a pocketknife or a tool with a sharp point to remove the O-ring from the groove in the starter drive housing .

Figure 16 Figure 13 13. Remove the starter drive from the starter drive housing

16. Re move the spring from the plunger in the star ter solenoid housing .

Figure 17 Figu re 14

14 . Remove the stee l ball from the hole in the shaft in th e starter dri ve. T his can be done by letting the starter drive fall on the bench from a height of 2 or 3 inches (60 or 75 mm ).

17. Remove the idler gear and thrust washer fro m the shaft in the sta rter solenoid hou sing .

Fig ure 18

Fi gure 15

8006A-9 18. Remove the 1h rust washer and beari ng cage assemb ly fro m the idler gear. Be careful not to lose the bea ri n gs.

20. Remove the cover fro m the sta rter sol enoid housing.

Figure 21 Figure 19 19. Remove the th ree Screws that fasten the cover to th e starter solenoid housing.

21. Remove the plunger from the sta rter so len o id housing.

Figure 22 Figure 20

006A- l0

INSPECTION All parts except the starter drive must be cleaned using minerai spi rits and a brush or cloth. Use a clea n , dry clot h to c lean the starter drive.

Armature 1.

Test th e armature on an arm ature tester Use the equipment manufacturer's inst ruc tIons .

Put the armature on vee-bloc ks as shown i Fig ure 24. Then use a dial indicator to check the runout of the commutator. The run ou t m ust no t be more than .002 inch (0.05 mm).

If necessary, put the arm atu re in a lathe and remove enough material from the com mutator to make the runout less than .002 inch (0. 05 mm).

B rushes and Brush Springs 1.

If th e length of a brush fastened to the brush ho lder Is less th an 7/ 16 inc h (11 mm), a new brush holder assembly must be used when the sta rter is assem bled.

If the length of a brush fastened to the field coil is less than 7/ 16 Inc h (11 mm ), a new field frame assembly must be used when the starter is assembled .

Use a spring sca le to c heck the tension of the brush spring s. Pu ll th e b rush spri ng up until the b rush spring is just above the brush holder. The scale indi cation must be between 4 and 9 po unds (1.9 and 4.0 kg) . If a brush spring does not meet this specificatio n, use a new brush sp rin g w hen the starter is assembled.

Brush Holder 1.

Use an ohmmeter o r other circ uit tester to make sure there is not a co mplete circuit betw een the brush holder fram e and the brush holders forthe brushes that are con nected to the field coli.

Fi gure 24 4.

Measure the diameter of the c ommutato r. If the diameter is less than 1.38 inch (3Smm ) a new armature must be used when the starter is assembled.

Fi gure 23 2.

If th ere was an indic ation of a complete circuit a new b rush hol der m ust be used when the starter is assembled .

Figure 25

8006 A- 11

If the d epth of the groove between the commutator ba rs is less th an .008 inch (0.2 mm), make the groove deeper. Cu t the insu lation between the com m utator bars to a dep th of .0196-.0314 inch (0.5- 0.8 mm) . Use san dpaper to remove the roug h edges from the commutator bars.

Field Coil Open Test 1.

Use an ohmmeter or other circ ui teste r to mak e sure the field coil is not open .

See Figure 27. Put one lead f ro m t he test in strument on the end of the cable fastened to the field coil and the other on one of the brush es connected to the field call. Th ere must be an indication of a co mp lete circuit.

Ch-eck the bearings on the armature for free rotation , rough balls, and damage to the inner race or outer rae . If a bearing is to be replaced, use a pre.....~ and acceptable tools to remove and install the bearing

Field Coil Tests

Field Coil Ground Test 1.

Use an ohmm eter or other circuit tester to make sure there is no t a comp lete circuit between field coil and the fie ld f rame.

See Figure 26 . Put on e lead from the test instrument on the fiel d f rame and the other lead on one o f the brushes connected to the field coil. T here must ne no indication of a complete circuit . Figure 27 3.

Figu re 26 3.

If there was an indication of a complete circuit, a new field frame assemb ly must be used when the starter is assembled.

If there was an Indication of an open circuit, a new field fr ame assem b ly must be used w~18n the starter is assembled.

8006A- _

ASSE 1.

Install he plu nge r in the starter solenoid housing .

SLY 4.

Put the grease specified on page 4006-3 in the slots In the beari ng cage. Then put a bearing in each slot. Put the same grease in the idle r gear teeth , Put the bearing cage in the idler gear an d put the thrust washer on top o f the beari ngs .

Figure 28 2.

Put

e ove on the starter s I nold housi ng. Fi gu re 31 5.

Put the grease specified on page 4006-3 on ttle shaft in the starter so len oid housing an d t he thrust washer. T hen in stall the idler gear on the shaft with thrust was her towa rd the starter solenoid housi ng .

Fi gure 29 3.

In tall and tight n the screws that fasten the ov r t 'he starte r solenoi d Ilousing.

Figure 32

Fi gure 30

8006A -1 3 6.

Put the grease specified on page 4006-3 on the spring . Th en put the spring on the plunger in the starter sol en oid.

Figure 33

Instal l the O -ring in the groove in the starter drive housi ng.

Figure 34

Put the g rease specified on page 4006-3 on the teeth at the front of the starter drive. Also put some grease on the O-ring in the starter drive housing . Th en start the starter drive into the starte r drive housing.

Put the starter drive housi ng assembl y o n the bench as shown in Figure 36. Push dow n o n t he starter drive housing to push the starter drive al l the way into the starter drive ho using

Figure 36

10. Put the g rease specified on page 4006-3 in the hole in t he end of the sta rter drive. Th en pu t th e steel ball in the hole in the starter dr i'J8

Figure 37 11. Align the starter drive ho us ing with the starter solenoid housing. Then push these parts together.

Figure 38

Figure 35

8006A-14

12. Put the starter drive housing in a vise as shown in Figure 39. Put the lock wash ers and flat washers on the screws that hold the starter drive housing and starter sol enoid housing together. Put new O-rings on the screws if necessary. Put a sm all amount of g rease on the O-rings . Then install and tighten the screws that hold the starter drive housing an d starter solenoid housing together.

14. Install the fiel d frame ho using. Engage the tab on the field frame with the notch in the sta rte r solenoid housing.

Figure 41 15. Install the brush holder on the commu tator.

Fig ure 39 13. Insta ll the armature In the starter solenoid hous-

ing . Figure 42 16. Use a pair of needle nose pliers to pull a brush spring away from one of the brushes In the brush holder. Push the brush down and put the brush spring on top of the brush. Repeat th is step for the other brush in the brush holder.

Figure 40

Figure 43

8006A-1S

17.

se a screwdriver to hold a bru h spri ng out of the way for o ne of th e brushes conn ected to the tiel coil. Put the brush in the brush holder. T hen ut the brush spring on top of the brush. Repeat this ste for the other brus h connected to th field o il.

19. Push the nd e ver against he field frame . Make sure he tab on t e fi eld fra me is in the notch in the starter s I noid hOLl sin g. Put the loCK wash ers and flat wash ers on the cap screws Put new O-rings on the cap sc rews if necessary . In tall and tighte n the cap sc rews that fasten the end cover and fiel d fram e to the starter solenoid housing .

Fig ure 44 Figure 46 18 . Pu the frame of the brush holder even with th e

en of the armature shaft. Put the end cover over the ru sh holde r. Alig n the small holes in th e en d cover wi t th e threaded holes In the frame of the brush hol der. Then in tall and ti ghten the screws that fasten the brush holde r to the end cov er.

20 . Put the cable on t he motor erm lnal Then install the lock washer and nut on the motor term inal. T ighten the nut. Put the rub ber bool over the

motor te rmlna .

Fi gu re 47

Figu re 45

8006A-16

1. CAP SCREW 2. LO C K WASHER 3. FLAT W ,A.SHEI;:!

7. BRUSH HOLDER 8. BEARING

13. PLUNGER 14. NUT

9 ARMATURE

15 . STARTER SOLENOID ASSEMBLY 16. THRUST WASHER 17. IDLER GEAR

4 . O-RING

10. FIELD FRAME ASSEMBLY

5 SCREW

11 . COVER 12. GASKET

6 EN D COVER

Figure 48

18. BEARING 19. BEARING CAGE

20. SPRING 21. STEEL BALL

22. STARTER DRI VE 23. STARTER DR IVE HOUSING .

8006A -17

STARTER SOLENOID TEST Th is tes t will check the condition of the pull-in i"ding and the hol d-in winding in the starter solenoid. The jum per cable connected to the starter mounting 11ange and the motor term inal must have a co m mon connect ion at the negative battery post.

Connect a jumper wire to the battery term inal and the switch terminal in tne sta rte r solenoid housing. The jumper wire m ust be made from No. 10 or larger wire.

Connect the jumper cable w ith th e common connection to the starter mounting flange and the motor terminal in the starter sol /l aid housing.

Starter Solenoid Test Procedure 1.

,emove the rubber boot from the motor termial. Remo ve the nut an d lock washer from the m otor term inal. Then remove the wire from the motor term inal.

C o nnect a jumper cable to the positive battery post of a fully cha rged 12 volt battery. Connect th e ot her end of the jumper cable to the battery term inal in starter solenoid housing.

+ 780515

3. 5.

12 VO LT B TTEFi Y STARTER 9ArrE RY TERM INAL SWITCH TERMI AL MOTOR TERMIN AL

NOTE:

Steps 5 and 7 must be do ne in a maximum of 5 seconds to prevent dam a e t o t he pullin winding and the hold-in wi r din g .

Connect the jumper cable with the c ommon connection to the negative battery post. Ttle pinion gear on the starterdrive m ust co me all tr,e way out rapidly and with force.

If the pinion gear did not co me o u t ra pidly and with force, the pull-in win d ing is damaged . T he complete starter solenoid housi ng assem bly must be replaced.

Disconnect the jumper cab le from the m o tor terminal in the starter solenoi d hous in The pinion gear on the starter drive mu st not move towa rd the starter drive housing.

If the pinion gear started to m e toward Ule starter drive housing, the hold-i n w indin g IS damaged . The complete starter sol eno id housing assembly must be repl aced .

Section 8007 ALTERNATOR

JICase A Tenn.oo ComDllfl'f

C. E. Dlv. 9-68015 _ _ .. y.u.

February 1976

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8007-2

· '1lI

TABLE OF CONTENTS Specifications

..••....•..•.•.•••••• •••.••••• ••••.••••••••••.• 8007-3

Alternatar and Voltage Regulator Testing

••••• •• •••••••••.••.•••.•••.• 8007--4

Prellmtnary Checks . • . . . . . . . . . . • • . • • • . • . • . • • . • . . • • . • • • • • • • • . 8007--4 Test Equipment

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8007-4

Prestol1te Alternator Tests . . . . . . • • • • •••••• ' , ' •••••••••••••..... 8007-5 ~

....... .

Test No, 1 - Alternator OUtput

Test No.2 - Voltage Regulator Setting

.. . . . . . . . . . . . . . . . . . . . . 8007-5

• • . • • . . • • • • • • . . • . . . . . . • • • 8007-6

Delco-Remy Alternator/Voltage Regulator Test

••••••••••••••••.. ... 8007-7

Prestollte Alternator ... •••.•••••••••. ...•••••••••.••••••.• •••.• 8007-8 The Alternator Charging CircuIt

••••••••.•••••••••••••••••••••.. 8007-8

. . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . .. . . . . . . . . . . 8007-9 Inspection . . . . . . . . . . . . . . . . . . . .•. . . .•. •.'. . . . . . . . . . . . . . . . . . . . 8007-9 Component Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8007-11 Disassembly

Assembly ..........•...•.••..••••••••••••••••.••..•••••• 8007-12 Delco-Remy Alternator

. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .

8007-14

The Alternator Charging C1rcu1t •. . •... ..••••••• •••.•.• .••..• .•. 8007-14

Disassembly .. . . • . . . . . • • • . • • • . • • • . • . . . . . . . . . . . . • . . . • ••••. 8007-15 Component Tests

.......•..••.••••••••••••••••••••• 8007-20 to 8007-23

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8007-23 Alternator Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8007-27 Assembly

.,~

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8007-3

SPECIFICATIONS Prestolite Alternator Alternator rated output

. . . . . . • . • • . • . . . . . . . 14.2 volts, 35 amps a.t 80· F. (26.7° C.) Output wUl decrease slightly as temperature increases and increase slightly as temperature decreases. Voltage regulator . . . . . . . . . . . . . . . • • . • . . . • . FUlly transistorized and nonadjustable Torque specifications Pulley nut . . . . . . . . • . . • • • • . . . . • . . . . . . . . . . • 30-35 foot-p:)\mds (41-47 N m) Brush bolder !Sorews . • . • • . . . . • • • • • . . . . 25-30 inch-pounds (2.8-8.3 N m) Auxiliary terminal nut - 10-32 . . . . •.•. . . . . .. 25-30 inch-pounds (2.8-3.3 N m) Output terminal nut - 14-28 . . . • . . . . • . . . . . . . .. 70-80 incb~pounds (8-10 N rn) Tie bolts . . . . . . . . . • . . . • • • • . . • . . • . . . . . . 35-40 inch-pounds (4.0-4. 5 N m) Dek:o~Remey

Alternator

Alternator rated output

. . . . . . . . . . . . . . . . .. . . . . 13 volts, 37 amps at 75° F (23.9 C) Output wUl decreaae slightly as temperature increases and increases slightly as temperature decreases. Voltage regulator . . . . . . . • . . • • • . . . . . . . . . . . Fully trWlsistorized and nonajustable. Torque spec1fJcatlonl:! "Pulley nut . . . . . . . . . • • • • • • . • • • • • . . . . . . . . . . 40-50 foot-pounds (54-68 N m) Bat termtnal nut ..•.• . • •.••• •••••...•... 25-40 inch-pounds (2.8-4.5 N m)

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â&#x20AC;˘

8007-4

â&#x20AC;˘

ALTERNATOR ANO VOLTAGE REGULATOR TESTING The alternator and voltage regulator re00 the machine whUe testing to use the circuit cooductors and accessories that are a permanent part of the charging system. This results in more accurate problem idenUiicatioo.

main

VAT-26 and Snap-en's Heavy Duty A.V.R. Tester. model MT 540C. The following test lllustraUoos will show individual compooent hookups but test may be performed ulling the self-cootained test equipment making connecUoos as instructed and according to the test equipment manufacturers instructioos.

Preliminary Checks Beiore testing the charging system check the following:

The following test equipment will be need6d to test the charging system. 1.

Battery post adapter, Figure 1.

Battery: The battery should be at least 751{ of full charge. Refer to Specific Gravity Check in SooUoo.

D.C. voltmeter, 0-40 volt scale.

8005.

D.C. ammeter. 0-100 amp scale.

CoonecUoo.s: All connectioos of charging system components shoold be tight and free of corr08I00, oxidatJoo and other foreign matter that would cause a poor coonectioo.

Rheostat, 0-50 ohms resistance, 50 watts.

1/4 ohm, 25 watt resistor. Sun Electric RES-lor equivalent with leads for CCllnectioo in the alternator output circuit.

Drive belt: The drive belt should be

Carbm pile, Sun Electric Y-20 or equivalent, capable of 600 amp load, knob cootrolled.

120 volt teet lamp with a 25 watt bulb.

Teat Equipment

12 volt teet lamp with number 57 bulb. Used during bencb testing.

NaTa: Tbe following test equipment, except the test lamp. are self-cootalned In SUn Electric's Volt-Ampere Tester, model

Ohmmeter, Simpsoo 260 or equivalent. Used during bencb testing.

free of grease or oil whiCh may

cause slippage under load. Check for proper belt tension as instructed on page 8007-27.

rtESATlVE('ABLE

."", Figure 1 - Battery Post Adapter

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8007-5

Prestolite Ahemator Tests

output terminal and the negative lead to the al temator [rune.

Test No .1 - Alternator Output 1.

COIUIect carba:! pUe (or l oad control) to tbe battery terminals. Make sure carbon pile is OFF before making camectioos.

stan engine and IUD at full throttle and open battery post adapter switch. AdJust the c8.l'bon pOe unUI the voltmeter indicates 14.2 volts. The test ammeter should indicate 35 amps.

'I\1rn of! cuba!. pile and stop engine.

If the output was nctasspecUied. remove altemator. disassemble Illld tost alte:ma-

Remove ground cable from battery. 10stall battery post adapter. Figure 1. 00 negative battery post and COMect cable

to adapter. NOTE: Hefore completing ~tep 2. cio3e switch on Sun adapter or turn switch nut up several turns on Snap-on adapter.

Connect test ammeter to battery post adapter as indicated in Figure 1. Connect voltmeter poSitive lead to the

tor compacent s.

,-----, c;.RBOII

PIL E

SOUtIOIO

• IAnERY POST ADAPUR (SMAP-OI')

I((STALL BAn{RY POST AMPlER ON It£c:ATTV£ !AmRY POST A!ID «WH£C1 SROOIIl CASU TO AD.lPT£iI. ' -_ _-' REFER TO FiGURE I FOR AOAI'TElS

TO ALTEIflATOil WARNING LtGHT

....,

Figure 2 - Alternator Output Test Hookup

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Test

No~

2 . Voltage

Start engine and :ntIl at 3/4 throttle for a tew mloutes to allow component temperatures to stabUl1.e.

With the engine runnlnr at full throttle, observe the voltmeter. The voltmeter ahoWd indicate 14.2 volts (slightly lower at temperatures above 80· F. (26.7- C) or slightly higher at tempera.tures below 80· F. (26.7· C.) for all machines.

Regulator Setting Remove (round cable from battery. IDstall~a.ttery peat adapter, Figure I, m negaUve battery post and OClUleot cable to .adapter.

•

'i8007-8·

Nara. Before completing step 2, close switch on SUn ·adapter or tum switch nut up several turns on Snap-on adapter.

Jl the voltage reading was lesa than. 14.2 volte the regulator is defective and must be replaced.

Cooneot test ammeter to adapter 8.8.indicated in Figure 1.

DiscCllDeClt wire from alternator output terminal and connect the 1/4 ohm re-

may be caused by a poor grOWld .between the regulator and the al-

sistor between the outpJt terminal and wire.

ternator frame or a defective regulator. Make repairs as required..

A voltage reading over 14.2 volts

Connect positive voltmeter lead to the alternator output terminal and negative lead to.tbe alternator frame.

After completing the teat, remove the 1/4 ohm resiator and cmnect wire to outpIt terminal.

, ;

TO STARTER SOlOOIO TERMIKAL

1/4 otII

•

IItSTSTOR

INSTALl MTTERV POST AflAPTER 00 HEGATIU POST NIl) COftflCT 6ROUIfD CABl[ TO ADAmI!. REfER TO FI6lJRf 1 FOR AOAPTEftS.

,...,

Figure 3 - Voltage Regulator Setting Test Hookup

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8007-7 Delco~Remy Alternator/Voltage Regulator Test

insert screwdriver more than one incb or unnecessary damage will result. With the engine running at half throttle, adjust the carbon pUe to obtain maximum current output. Record test ammeter reading and turn carron pile off.

Remove ground cable from battery. Install battery post adapter, Figure I, on negative battery post and connect cable to adapter. NOT_I Before completing step 2, close switch on the Sun adapter or turn the switch nut up several turns on the SnapOn adapter.

Connect test ammeter to battery post adapter as indicated in Figure 1.

Connect carbon pOe (or load control) to the battery terminals. Make sure carbon pUe is OFF before making connections.

Start engine and run at balf throttle and open battery post adapter switch. Then adjust carbon pile to obtain maximum current output (amperes). Record test ammeter reading and turn carbon pUe off.

If output was within 10 amps of the spe-

Figure 4 cified output (37 amps), the alternator and voltage regulator are good. Low output within 10 amps could be caused by poor connections in the charging circuit. Check and clean circuit connections as required. 6.

If output was not within 10 amps of the specified output (37 amps) ground the

field winding (rotor) by inserting a screwdriver into test oole 10 rear oousing, Figure 4. The screwdriver should contact tab in bole and rear oousing. Do not

If output in step 6 was within 10 amps of the rated output (37 amps). remove alternator, separate the front and rear housings and perform rotor tests as instructed on page 8007-22. If rotor tests good, replace the voltage regulator.

If output in step 6 was not within 10 aJJt)s of the rated output (37 amps),

'remove and disassemble the alternator, and check the rotor, diode trio, rectifier bridge and stator as instructed under Component Tests starling on page 8007-20.

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•

8007-8

•

PRESTOLITE ALTERNATOR The Alternator Charging Circuit The charging circuit consists of the battery, alternator, voltage regulator, key switch, 4() amp circuit breaker. alternator warning llght and related wiring. The circuit is schemaUcally illustrated In Figure 5.

....

'U "'!"'"

CIRC. 8R£AK£R

AlT. WARN. LIGHT

-,;:;;;.;;:; HARNESS PLUG

stator windings. This alternating current is then rectified (changed to D. C.) by the rectifier diodes and delivered to the outplt terminal. Diodes have a high resistance to current flow in ooe direction and a low resistance in the opposite directioo. They are connected to permit current flow from the alternator to the battery in the low resistance direcUCIl . The high resistance of the opposite direct100 prevents the flow of current from the battery to the alternator. Residual magnetism in the rotor (field) is negligibl e, therefore. a starting field current must be supplied from an external source. Initially the battery Is coonected to the field winding througb the key swItch and regulator and supplies field current until the alternator output overcomes the starting field current. Wben this occurs, the field winding is energized by the alternator through the voltage regulator and the warning light indicates a charging condition. This eliminates the need of the external field current source and results in an almost complete el1m1natioo of the voltage drop between the alternator and the auxiliary terminal where system voltage 1s sensed.

Figure 5 - Charging Circuit The alternator components are the !root housing, stator ,rotor and rear housing which contains the rectifier diodes. By rotating the rotor inside the stator., an alternating current is induced in the

The alternator output is regulated by varying the field current. This i8 accomplished through the use of a completely transistorized voltage regulator which tums 00 and shuts off the field (rotor) and maintains a predetermined voltage.

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8007-9

Diaa.embly 1.

Scribe an and rear assembly. lator Crom

aHgnmeDt mark: OIl the front bOUsings to a.66ure proper Then remove voltage regurear housing.

Remove the thrU bolts USing a 3/16" (4.8 mm) 81x point socket. Separate the front houaing and rotor LBsembly from the rear housing and stator assembly. It may be nece88ary to drive tbe rear housing from the rear bearing. Use a drL!t punch and Ught hammer. Place puDch near thru bolt bosses on rear hoUSing. Figure 6 - Removing Front Housing Bearing Use care when handling the stator and rear housing to prevent damage to Âˇthe winding Insulation. stator and diode leads. NOT~

Remove brush bolder assembly Crom rear housing.

Secure pulley In 80ft Jawed vise and remove nut and lock washer. Then remove pulley. fan, Woodruff key' and spacer.

Jl!ace front housing in a. press with rotor dotllm. Properly support housing and press rotor out of tront bousing bearing. Do not allow rotor to drop. Then remove felt retaJners and felt from rotor abaft..

Remove bearing from rotor shaft cnly if inspectloo tndlcates need for replacement. Provide su itabl e support for the bearing and press bearini from slla.ft..

Remove snap ring from froot housing. Support the front housing c;n the bearing bou and pre8~ hearing from houSing. Figure 6.

The stator leads must be unsoldered trom the diodes to aoouratel.y te. t the stator and dIodes. Use a press to remove and install the diodes. The output and auxUiary term.lnals must be

removed to remove the dlode/heat sink usembly.

Inspection 1.

Clean the front and rear housings in Cleaning solvent and wipe the remainIng parts wltll ~ SOiVCSlt dampened cloth.

Inspect froot and reu housings for c racks and other detects.

mspect rotor and etator Cor discolored Discolored windings may be the resul t of sborted windings or overbeating. windings.

4..

Inspect brusbes for wear IiIld oll Cat ta.m.lnatioo. When brusbes are worn to 1/ 4" (6.4 mm) or less, they must be replaced. The complete brush bolder assembly must be replaced. wben brushes require replacemoot.

Check brush spring tensioo. The spring tensioo should be great enougb to bold the brus b firz:nly aga.lnst the slip rina:.

Check bearings for free rotation, .Qat spots and cracked races.

Discard any cracked insulator.

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•

••

- { - , @IIINERFEtTRETAINER

'VI V,

-I

',,-

FELT

BEARING

", r .... OtrrPlIT DIODE HEAT SINK' DIODE (POS.)

r.... '

I ',- -

~~ ~

"Q9';",

fl..

"'MSULATOR W

~./IJ./ I <?9 f).'>":t.> I

INSULA~OR

.&.umJJ.RY

STUD

•

"""

,"'0

OUTPUT

~IfW.

"<~ ~

TERI1I~ POSITIVE ~ OIOOE

IS01111

O-RING

Figure 7 - Alternator

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•

• 8,

8007-11

Check for loose diodes In heat sink and .rear housing.

Clean brush ccntact surface

811prings

"with crocus cloth.

Component Testing

Rotor Short Test 1.

Refer to FIgure 8 and set up test as Ulustrated.

Set rheostat at maximum

resistance before making connections.

Figure 9 - Testing Rotor for Ground betweE!l the diode and soldered connectioo

RH£OSTAT

to prevent heat damage to the diode. 2.

ROTOR

,,"'"

Toucb OIle probe of the 110 volt test lamp to the stator frame and the other probe to a stator lead. Repeat for the remaining stator leads. If the test lamp lights, the stator is grounded and must be replaced.

Stator Open Test

Figure 8 - Rotor Short Test Hookup 2.

Slowly reduce resistance until the voltmeter indicates 10 volts,

Note the ammeter reading. The ammeter should indIcate 2.4-2.6 amperes. ExcessIve amperage indicates shorted windings and a .zero reading indicates an open winding.

Rotor Ground Test

Shorted Stator

Place one test probe en a slip ring and the other probe 00 the rotor core as illustrated in FIgure 9.

Shorted windings 1n the stator are difficult to detect If the rotor and rectifier diodes are noLthe cause of fallure. and the stator laaot open or grounded, replace the stator.

Stator Ground Test

Testing Rectrfter Diodes

Touch one probe of the 12 volt test lamp to the stator oommon connection, FIgure 10, 'and the other test probe to a stator lead. Repeat for the .remaining stator leads. ]f the bulb falls to light, a winding is opeo and the stator must be replaced.

Unsolder stator leads If this has not been da'te. NOTE: When unsoldering or soldering

stator leads, grasp dIode lead wIth plIers

Diodes may be tested with a 12 volt test lamp. ohmmeter or a commercial diode tester. II a commercial diode tester is available, test the diodes according to the equipment manu.fa.cturer's instructioos.

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8007-12 b.

Connect 12 volt battery and the test lamp to each negative dlcxJe as illustra.ted in Figure 12. Refer to Figure 10 for diode location. The lamp should I1ght in cne direction only. If the lamp falls to light or lights in both directions, the diode is defective and must be replaced.

tAKP SHOULD LIGHT

lAHP SHOULD NOT LIGHT

Figure 10 - Diode Location 1.

Unsolder stator leads from diodes if this has not been done. NOT.: When unsoldering or soldering diodes, grasp the diode lead with pliers between the dIode and soldered connection to prevent beat damage to the diode.

V BATTfRV

12 v BAnERV 12076ÂŤ

Figure 12 - Negative Diode Check

To check the diodes with a 12 volt test lamp:

To check diodes wIth an ohmmeter, oon-

nect one test lead to the diode lead and a.

Connect a 12 volt battery and the test lamp to each positive diode as illustrated in Figure 11. Refer to Figure 10 ror diode location. The lamp should Ught in one .direction only. H the lamp fails to light or lights in both directions the diode is defective and must be replaced.

"'" ___ '" NOT liGHT

12 V BATTERY

the other test lead to the diode body. Note the reading and reverse the test leads. The diode is good if there was a high and low reading for each diode. H both readings were the same, the diode must be replaced.

Assembly 1.

Press bearing into front housing and secure in place with snap ring.

Press bearing onto slip ring end of rotor. If the bearing Is open on one side, install bearing with sealed side toward the rotor core. Pack bearing with a good grade of high temperature bearing grease.

Place inner felt retainer on rotor shaft. Then place felt and outer felt retain e r in the inner felt retainer.

Start front housing onto rotor shaft. Place this assembly in a press, rotor down, and press hoUSing onto shaituntil seated. Use a driver that fits over the s haft and contacts the inner bearing race.

LAMP SHOULD LIGHT

Figure 11 - Positive Diode Check

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8007-13 5.

Install spacer en rotor shaft. Then place Woodruff key in keyway and install the fan and pulley. Secure parts in place with lock washer and nut. Torque out to speci!1catioo on page 800 7-3.

Make sure O-ring is in bearing bore in the rear hOUSing. Stand front housing 00 pulley and start rear housing/stator assembly 'Qlto bearing. Align marks made on front and rear housing and start the four tie bolts into place. Alternately tighten two opposing bolts to draw the housings together. Tighten the rema..lning bolts and torque all tie bolts to specificatloo on page 8007-3.

Install brush Mlder assembly in rear

MUSing. Place cover on fiat surface of rear housing bearing boss. Then set brush bolder on cover and push brusb Mlder down and Into rear housing. Listen for click as each brush contacts the slip rings. Install cover over field terminal and secure parts in place with screws. 8.

Figure 13 - Installing Front Housing Bearing

Secure voltage regulator to rear housing with screws. Tbe black lead should be attached to regulator mouoting screw. The brown lead is connected to the auxiliary terminal and the green lead to the Held terminal.

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â&#x20AC;˘

8007-14

â&#x20AC;˘

DELCO-REMY ALTERNATOR The Alternator Charging Circuit The alternator charging circuit consists of the battery, alternator with self contained voltage regulator. key switch, 40 ampcfrcuit breaker, alternator warning light Wld related wiring. The circuit is schematiCally illustrated in Fi8!Ue 14. " AMPBREAKER CilIC.

,â&#x20AC;˘

Figure 14 - ChlLrgJng Circuit The alternator components are the front rousing, rotor. rear bousing, diode trio, rectifier bridge Wld stator.

By rotating the rotor inside the stator, an alternating current is induced 10 the stator winding. Th.is alternating current is then rectified (changed to D.C.) by the rectifier

diodes In the :rectifier bridge and delivered to the Bat (output) terminal. Diodes have a high resistance to current flow in one direction and a low resistance in the opposite direction. They are connected to permit current flow from the alternator to the battery in the low resistance direction. The high resistance of the opposite direction prevents the flow of current from the battery to the alternator. Magnetism in the rotor (field) is very slight, therefore, a starting field current must be supplied from Wl external source to start the alternator charging. Initially the battery is connected to the field w.inding through the key switch and regulator, and supplies field current unW the alternator output overcomes the starting field current. Wben this occurs, the field winding is energized by the alternator through the voltage regulator and the alternator warnJng Ught indicates a charging condition. This el1.minates the need of the external field current source and results in an almost complete elimination of the voltage drop between the alternator Bat terminal and terminal NO.1 where system voltage is sensed. .The alternator output is regulated by varying the field current. This is accomplished through the use oC a completely transistorized voltage regulator which turns on and shuts off the field and maintains a predetermined voltage. The condenser mounted inside the rear housing is used to absorb transient over voltages that may damage the diode trio or the diodes in the rectifier bridge. Whenever the dJode trio or the rectifier bridge is found to be defective, it is suggested that the condenser be replaced as a protective measure.

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8007-15

Disaasembly 1.

the ohmmeter leads and note ohmmeter reading. There must be one high and one low reading. If both readings were

Make an alignment mark on the front and rear bousing to assure proper as-

the same. remove the brush lead clip screw and c heck insulator Cor damage. If

sembly. Then remove the four tie bolts and separate the housings . Be sure the

the insulator Is good. the vollageregulator is damaged and must be replaced.

stator and rear housing are moved as an assembly.

1. Insulator

Figure 17 3, 1. Alignment Marks

Check insulator on both insulated screws for wear or damage that could result in the connected parts being grounded.

Figure 15

Before disassembling the rear housing, connect an ohmmeter, set on the lowest scale, to the brush lead clip and rear bousmg as illustrated in Figure 16 and Dote the ohmmeter reading. Reverse

1. Ohmmeter "2. Brush Lead Clip Screw

Figure 16

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8007-16 4.

Remove nuts from rectifier bridge terminals and insulated s crew from long leg of diode trio. Then remove stator and diode trio from rear housing.

1. Diode Trio

Figure 20 5. 1. Nut 2. Insulated Screw

3. Diode Trio 4. Stator

Remove nut {Jer bridge denser lead tifier bridge

from Bat terminal, recUretaining screw and conscrew. Then remove recfrom rear tX)uelng.

Figure 18

1. Bat Terminal Nut 2. "Rectifier Bridge Screw 3. Condenser Lead Screw 4. Rectifier Bridge

Stato r Figure 19

Figure 21

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8007-17 6.

Remove Bat terminal and insulator from rear housing. Discard insulator if it is damaged in any way,

U the bnlSbes measure 13/32" (10.3 mm) from the shoulder to the slip ring surface, the complete brush rolder assembly must be replaced. HOTE: Check with local Delco-Remy parts supplier to see if brushes can be purchased separately.

1, Bat Terminal

2. Insulator

Figure 22 7.

Remove the grounding screw holding the

brush holder assembly and voltage regulator and remove these parts (rom the rear housing. Tben remove condenser (capaCitor) from rear housing.

1. Grounding Screw 2. Brush Holder Assembly

3. Voltage Regulator 4. Condenser (Capacitor)

1. Brush Assembly

3, Brush Holder

2. Brush Spring

Figure 24

1. Voltage Regulator (Regulators May Vary in Appearance but are Completely

Interchangeable) Figure 25

Figure 23

(

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•

8007-18

Donat remove bearing from rear rousing unless it is to be replaced. Reasons for replacement are; worn or damaged seal and/or bearing rollers. and lack of lubricant. 00 NOT attempt to lubricate bearing.

•

11. Secure pulley in a soft jawed vise and

loosen nut. 12, Remove nut. lock washer. pulley, fan

and spacer from rotor shaft. 13. Remove front rousing from rotor,

1. Bearing

-1. Front Housing

2. Rotor

Figure 20

:Figure 28

10. To remove bearlng from rear rousing.

support rousing under bearing bore wIth a piece of pipe or other suitable support. The support must be long enough to p~e vent the rousmg from touching the work bench or press bed. Then use a suitable driver and press or drive bearing Jrom rousing.

14. Remove beating reta.1ner cap screws. The flanges .of the screw heads are upset to lock the screws in place. discard screws and replace with new parts.

1. Bearing Retainer

Figure 27

Figure 29 •

)

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•

f''' . •

-'-

~ @17

8007-~9

". ,.3.,.

••

PULLEY IlIT

,0« """

"'ll'

.,,'" •••• '"

flI:OIIT IIlUS IllIG

FLAT IoIo\SHfR

8. IIIU. IlEARIII8

•• 10.

II. 12 . Il. It.

&WING IETAIIIER

'" """ """ 0.''''''' """ STAl\III

15. IIASHOt MUD SCIID/ 16. IIlSY..AT£O SCRtV 11. OtOD[ 1110

lIlT

20. 21.

ArmfUl!: 111106£ BRUSH DDEI

""" ""

n. 2l.

". 25.

". 'L n.

8lal$II SPItiNG BRUSH ASSo.tY YOLTAGE UIII,l.AT(lII

REAR IIIJSIIIIi IIE!lU IEAIUNG III'StU TOIl &AT TUMIIW.

Flgure 30

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•

8007-20

•

Component Tests

15. Remove bearing retainer. A felt sealls installed in the retainer. Replace the retainer if the felt seal is 'NOm or

Diode Trio Test

damaged, or hard,

1. Diode Trio 1. Bearing .Retainer

2. Ohmmeter Figure 33

2. Felt Seal

Figure 31

Refer to Figure 32. Connect the ohmmeter leads to polnts A and B and note ohmmeter reading. Then reverse leads and note ohmmeter reading.

Repeat step 1 at points A and C.

Repeat step 1 at points A and D.

If there was one high and low reading in steps 1. 2 and 3, the diode trio is

16. Remove bearJng and flat washer from front housing. If necessary, press bearing from housing. Be sure to use a

suitable support WIder the center of the housing.

good. 5.

If both readings were the same in either step 1, 2 or 3. the diode trio 1s defec-

tive and must be replaced.

1. Bearing 2, F1at Washer

3. Front Housing

Figure 32

•• •

)

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8007- 21

Rectifier Bridg e Te st The rectifier bridge has three diodes connected to the grounded heat sink and terminals, and three diodes connect ed between the insulated heat sink and terminals. U one diode is defective , the complete r ectifier bridge must be replaced.

reverse the leads and note the ohmmeter reading. 4.

Repeat step 3 for the r e maining insulated heat sink diOdes.

U each pair of ohmmeter . readings indicated one high and one low reOOinf/:, the rectifier bridge lB good.

U one pair of o hmmeter readings was the same. that diode is defective and the rectifier bridge must be replaced.

Stator Tests

1. 2. 3. 4.

Rectiller Bridge Grounded Heat Sink Insulated Heat Sink Ohmmeter Figure 34

1. Stator

2. CIlmrneter Figure 35

Refer to Figure 35. Connectanohmmeter to points D (oommon connecUon) and E (stator laminations). U the ohmmeter needle moves. it lndicates a gTOWlded winding and replacement of the stator.

Refer to FIgu.re 34. Connect the obmmet~J" leads to the grounded hent sink and ODe of the metal diode connectors and note the ohmmeter reading. Then reverse the leads and note the obmmater reading 00 NOT connect ohmmeter lead to the terminals a3 a false r eading may result.

Connect ohmmeter leads to points A and D and note ohmmeter readinll.

Connect ohmmeter leads to points B and D and note ohmmeter reading.

Repeat stop 1 tor the remaining groun ded heat sink diodes.

Connect ohmmeter leads to points C and D and Dote ohmmeter reading.

to move in e ithe r step 2, 3 or 4, a w10dlng is open and the s tator must be replaced. oont' d on next page

Refer to Figure 34. Connect the o hmmeter leÂĽds to Ute in:nullted beat sink and one of the metal diode connectors and note the o bmmeter reading. Then

If the ohmmeter needle faUed

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8007-22 6.

A short circuit in the windings is dlfficult to detect. If the diode trio, rectifier bridge, rotor md voltage regulator all checked out good. and the reason for alternator disassembly was low output. shor ted stator windings are indicated. Replace the stator.

Rotor Short Test

12 VOLT BATTERY AMP· METER

A shorted stator can cause the warning light to come on at lower engine speeds. NOT_:

Rotor Inspection .

" • • "

Figure 37 1. l. Slip Ring 2. Bearing Area

3. Slip Ring to Winding Connection Figure 36 1. 2.

Inspect rotor sbaft in bearing area for wear pitting and flat spots.

The ammeter should indicate 4 to 4.5 amps with a rotor temperature of 80· F (26.7· C). The reading will be slightly higher if the temperature is lower or slighUy lower if the temperature is higher.

A reading above the specified amperage Indicates a shorted winding and replacement of the rotor.

A reading below the specified amperage indicates excessive resistanc e and replacement of the rotor.

An alternate method of cbecking for a shorted winding Is to connect an ohmmeter to the slip rings as shown in Figure 38. The ohmmeter should indicate 2.7 to 3 ohms at 80· F (26.7· C).

Check for loose rotor windings. If windIngs are loose; replace the rotor.

Check for broken s l1p ring connections.

Clean dirty Slip rings using 400 grit or finer emery cloth. The rotor must be rotated to prevent flat spots on the sUp rings.

II slip rings are rough or out of TOWld they should be cleaned up in a lathe to .002" (0.05 mm) maximum indicator reading. Remove only enough material to make sUp rings smooth and I'OWld. Finish with 400 grit or finer emery cloth.

Refer to Fiaure 37, Connect Ii new 12 volt battery or a used battery that is known to be good. and an ammeter to the side of each slip ring and note the ammeter reading. The connections to the slip rings must be made on the side to prevent damage to the brush surface on the rings.

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8007-23

Tbe ohmmeter reading will also vary when tested at higher or lower tem-

A ... mbly

peratures. A reading blaber or lower than apecUied indicates replacemeat of thtJ rotor.

U bearinl was removed.!rom rear housing. pres. or drive in a new bearing. The housing must be supported under the bearing bore and the support must be long enough to prevent the housing from touching the bench or press bed. Drive bearing in until flush with outer end of bearinl bore.

1. Rotor 2. Ohmmeter

3. SUp Ring

Figure 38

Rotor Ground Test

Figure 40

1. Rotor

Secure oondflll.S8r to rear housing and place voltap regulator in housing as illustrated in Fl&ure 4.,

2. Ohmmeter

Figure 39

Connect an ohmmeter to a sUp ring and the rotor shaft and observer ohmmeter. If the ohmmeter needle moves, the winding

is pWlded and the rotor must be replaced.

1. Condenser

3, Voltage Regulator

2. Rear Housing

Fl&ure 41

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8007-24 3.

If bruShed were removed from holder, Install bruShes as illustrated in Figure 42. Then push brushes into holder and hold bruShes in place by insertlng a tooth pick or piece of wire _-through holes in brushes and holder. The Âˇwire or tooth pick should be installed so' it can be .removed after the front and rear housings have been assembled.

Install Ins,ulat.lU!. scr.ew in top holfl in br:ush holder. Do not install the I re-maining insulated screw at this time.

1. -Insulated Screw Figure

ÂŤ

,Install insulator on Bat terminal and install terminal assembly in rear housing.

'Figure 42

Place brush holder assembly on top of voltage regulator and install the ground screw illustrated in Figure 4.

l . ..J:nsulator 2. B"at Terminal

3. Rear Housing Figure 45

1. Ground Screw 2. Insulated Screw Holes Figure 43

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â&#x20AC;˘ 7.

8007-25

Place rectifier bridge in rear housing as illustrated in Figure 46. Secure bridge in place with nut on Bat terminal and ground screw with attached washer. Then secure condenser lead to rectifier bridge.

Install stator in rear housing and place leads on rectifier brtdp;e terminals.

Figure 48

1. RecUfier Bridge 2. Bat Terminal Nut

10. Install nuts on rectifier bridge terminals and mstall the remaJning insulated screw, Figure 44, in location soov.n in Figure 49.

3. Ground Screw/Viasber Assembly 4, Condenser Lead Screw Figure 46 8,

Install diode trio on rectifier bridge terminals.

1. Terminal Nut

2. Insulated Screw Figure 49

Figure 47

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8007-26 11. mata1! flat washer and bearing in front roUSing. Sealed side of bearing must be toward washer. If or iginal bear ing is being used, fill bearing 1/ 4 full of Texaco RB grease o r equivalent. Overfilling may result in overheating and early bearing failure. Mter bear ing has been installed, fill cavity made by the bearIng and bearing retainer with the spec ified grease.

13. Installl rotor in front rousing and fan spacer on r o tor sbaft.

Figure 52 14. Install fan and pulley on rotor shaft.

1. Fla t Washer 2. Bearing

3. Front Housing

Figure 50 12. Ins tall bearing retainer in front housing

using new cap screws . Use a hammer and punch and bend flange on screw heads down to lock them in place. Figure 53 15. Secure pulley in place with lock washer and nut. Torque nut to specification on page 8007 - 3.

Figure 51

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. ".

8007-27

16. Assemble front and rear hoUSings. alignment marks lined up. Install tie bolts and torque to specification on page 8007-3.

17. Remove tooth pick or wire from brush holder.

1. Tooth Pick or Wire

1. Alignment Marks Figure 55

Figure 54

ALTERNATOR BELT ADJUSTMENT The alternator drive belt should be

checked for looseness and wear after every 100 hours of operation. The pl'q)er belt adjustment will result in 1/2"

pump bearings will resull H the belt is too loose, the belt will slip resulting in wear and low or no alternator output.

(14.7 mm)

belt deflection v.nen measured between the alternator and fan pulleys. If the belt is too

NOT.:

belt,

pry

When adjusting the alternator against

the

fr(Il.t bous.ing only,

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Section 8015 ElECTRICAL ACCESSORIES

J I Case

A TennecoCompan y

C. E. Dlv. 9-66015

Fe bruary 1976

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8015-2

TABLE OF CONTENTS Cab Lights with Dual Rear Floodlights . . . . . . . • . . . • . . . • . . . • . • • • • . • . . • •. 8015-3

Front and Rear Wiper Installation

••....•••••••••.•.•••••••••••••••. 8015-4

Cab Heater and Defroster Installation

. . . . . . . . . .. . . . . . . . . . . . . .. . . . . . .

8015-5 8015-6

Heater and Defroster

Canopy Lights with Dual Rear Floodligbts . . . . . . . . . . . . • • • • • • . . • . . • • • • • .. 8015-7 Canopy RotatIng Beacon Installation . . . . . . . . . . • . • . • . . . • . • • • . . . . • . . . . • 8015-8 Cab and Canopy Lights with Single Rear Floodli2ht . . • . . . . . • • • . • • • • • • . • . . • , 8015-9

Backup Alarm Installation Horn Installation

....••••••..•......••••••••••••.•...•.

8015-10

. . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8015-11

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8015-3

(

.r"

• NOTe SH S£CTIOII 800l fOR Wl lt l ..

DfAGAAII.

Figure 1 - Cab Ligbta with Dual Rear Floodlights

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•

8015-4

•

FRONT WIPER

•

REAR WIPER

Figure 2 - Front and Rear Wiper Installat10n

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8015-5

~ o

oo •

••

1'0 KH SII\fell ,Q,CC. TERllIlIAI.

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Figure 3 - Cab Heater and Defroster Installation

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• ·8016-6

••

.. Figure 4 - Beater and Defroster

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8015-7

. •

_-., SEE SECTION 1003 FOJI

lllUN!> DI.IoGAAM.

Flaure 5 - Canopy L1gbts with Dual Rear Floodlights

'J':

-.al- •

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•

8015-8

.•

fo1f.1fo1

ts,,.

TO KEV SWITCH

TERH INAL

.,-·":1 ..

)

,I I

•

III

L Figure 6 - Canopy Rotating Beacon Installation

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â&#x20AC;¢ 8016-9

COMBINATION FlOOD NfO TAILliGHT

FRONT LIGHT

Figure 7 - Cab or Canopy Lights with Single Rear Floodlight

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•

80,15-10

F-I~~l"

•

lin

SLlTCH

ACC. llRH11IAl

MOUNTING BRACKET FASTENED TO CROS~ER BEHIND SHUTTLE LINKAGE BElLtRANK

ItlUNTING ~LATE FASTENED UNOER FLOOR PLATE USING

BOlTS TO ANC~ L.H. SEAT BELT BRACKET.

@!l

~I ""

1/",0<:

"'"

Figure 8 - Backup Alarm Installation

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80.15-11

• FASTEJlEO TO RIGHT-llANO

SIDE Of

RADI~TOR

SHROUD

°AU., ff"~"91 BAT...

TO I(£l SWtTOi

ACe. TrRMIIW.

•

WIRE CONNECTS TO CIRCUIT BR£AXER BEACCII IS !lOT IJSUI NID TO CIRCUIT

B IF BEACUI IS USED.

, Figure 9 - Horn Installation

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Section 9010 LOADER

J I Case

A Tenneco Company

C. E, Dtv. 9-66015 February 1976

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9010-2

TABLE OF CONTENTS Standard Bucket

9010-3

Cutting Edge ~emoval and Replacement. . . • • . . . . . . . . . . • . . • • . • . . . . .. 9010-3 Clam Bucket . . . . . . . . . . . • . . . . . . . . . . . . . . • . . . . . • . . . . . . . • . . • . . . . . 9010-4 Clam Cutting Edge Removal and Replacement . . . . • • . • • • . . • • • • • • . . • . .. 9010-4 Blade CUtting Edge Removal and Replacement

Bucket Teeth

.•.••. .. . . . . . . . . . . . . . . . 9010-4

• • . . . . . . • . . . . . .•... " • • • • • • • . • . . . . • • • • . • • • . . . • • •.

9010-6

Tooth Shank Removal and Insta1laUoo . ".•••••. _ . . . . . . . • . • . • • • . . . . . . .

9010-6

Tooth Replacement ... .. . , ... . ..•. . --;. . . . • . • . • • • . • • • . • . . . • • • . ..

9010-6

... . .

. . . . . . . . .. .. . . . . . . . . .... . .. ... ... . .. .....

Return-to-Dig . • . . . . .. . . . • • • . . . , ..•••. General •• ...•. , • •.•.•.•.• •. •••• ..

9010-7 9010-7

Adjustment . . . . . . . • . . . . . • .• .• . .•.• • . . . • . • . . . . • . . . .. • ' . . . ..

9010-7

9010-8 ... . -. . . . .. . .. . 9010-8 Operation . . . . ... , . . . . . . . . . . .. .. . . . . . . . . .. . . . . ... . . . .. . . . 9010-8 Adjustment . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 9010-8

Antirollback G<neral

. . . . . . . . . . . . . . . . . . ... -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. .. .. . . . . . . . . . . . . . . . . . . .

loader Arm • . . • • . . • . . . . • • • . _••• . . . . . ..•. _• . _. • • • . • • . . . . . . . • . . .. 9010-9 Removal

•

9010-9

Jnstallation . . . . . . • • • .. ...•••• ___'' '. _•••••••••••.••• ' •••••••...• 9010-9 Loader Arm . . . . . , . . . • . . . . . • . • • • . • • • . • • . . . . • • . . • . • . . . . . . . • ..

9010-10

Basic Hydraulic In.atallation . . . . . . . . . ••..

9010-11

•

••

•

••

Lift Cylinder HydrauHc InstallaUon . . . . . • . . . . . • . • . • . • . • . • • • . . . • • • • .

9010-12

Bucket Cylinder Hydranllc Installation . . . . . . . • . • • . . • • . . .• ••.••. . . . . .

9010-13

Loader Arm Hydraulic Installation. . . . . . . . . . • . . . . . . • • • . • • • • • . . • . . ••

9010-14

Return-to-Dig and Antlrollback: Linkage . . . • . • . . . . . . . . . . . . . • • • . • . . . . .

9010-15

Control I.ever Installation . . • . . . • • . . . . . . : •.•••. • . _. . . . • . • . . . • . . . •.

9010-16

Clam Bucket . . . . . . . . . . . . . . • . • • • • _•• ,0 ••••••••••• _. • • • • • • • • • • . ••

9010-17

Front Counterweight Installation .•• •' .•• _• . • . . . • . . • • . • "•• ~ • • • . . • . . ..

9010-18

Rear Counterweight Installation ..••.• . • ,~

9010_19

. " •••••••••••

~":. .

•

••

)

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9010_3

STANDARD BUCKET Cutting Edge Removal and Replacement

Start at one end of the bucket and weld toward the center until one .rod

Is used. If the bucket is not to be removed, disconnect the w1r1ng from alternator and voltage regulator. Also block the bucket in position to prevent personal injury. NOT~

Remove bucket teeth ff so equipped. Use carbon arc rod or an a.cetelyne cutting torch to remove welds.

Remove all cutting edge welds using

Repeat at the center of the bucket. On succeeding center Âˇ\Veldsworkout from both sides of center.

Repeat step 6a at the other end of the bucket.

Continue \Velding In this manner until the cutting edge Is completely welded.

carbon arc rod. If carbon arc rod is. DOt available an acetelyne cutting torch

may be used but care should be taken to keep distortion to the m1n1mum.

3..

/ / 1

I 1 I I

Remove the cutt1ng edge and grind off any remaining weld and/or excess metal

to provide a smooth surface for the new

cutting edge.

Place cutting edge OlUqHI to bold it weld rod meetlng E-701B, lUI opening

I I

1n position. Ulling a

front of blcket:

~--F"'2

) - _ _ C-_-

A. W,S. specification

Refer to Figure 1 and weld cutting edge to bucket. Use weld rod specified in step 5. \\'hen welding cutting edge to

I I

I k " L.. __ _

on bucket, using Cmade ineachcorner.

Cut off the wrap around ends of the cutting edge_ Cut through from the Inside corners of the rocket.

I 1/4" (6. 4

FILLET 3/16 ' ( '. 8 ... ) FI LLET 1f4" (6 .4 l1li) FIllET 5' 027 . .) waDS OH 10' (ZS4 _ J coous

~IU'

Figure 1 - Cutting Edge Welds

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â&#x20AC;˘â&#x20AC;˘

9010-4

CLAM BUCKET Clam Cutting Edge Remove. end Replacement

ceedlng welds work out from both sides of center.

N~ If the bucket Is not be be removed. d1.IoonDect the wiring from the alternator and regulator. Also block the bucket in position to prevent personal injury.

Remove all cutting edge weldsus1ngcarbon arc rod. An acetelyne cutting torcb ma,y be used but care .should be taken to keep distortion to the minimum.

2..

Rer:nove the cutting edge. If necessary. cut at! the wrap a.round corners of the cutting edge to aid In removal.

Grind any rema.1nlng weld of! the clam to pI1JVlde a. smooth surface for the new

Place cutting edge on olam using Cclamps to bold It in position. PosiUon cutting edge as sbown in Figure 2. Weld cuttlng edge to bucket uslDg E-7018 welcUng rod. Refer to Figure 2. To pretent distortion weld the cutting edge as follows:

Repeat step 5 .. atothereDdofbucket.

Cont:1.nu.e welding in this manner until the cutting edge is completely welded.

Blade Cutting Edge Removal and Replacement NOT&: If the bucket i8 not to be removed, disconnect the wiring from the alternator and regulator. Also block the rocket in position to prevent personal injury.

Remove all cutttng edge welds using carbon arc rod. AI1 acetelyne cutting torch may be used rut care sbould be taken to keep distortion to the minimum.

Remove cutting edge.

Grind the rema.1nJng weld off the blade to provide a smooth surface for the DeW cutting edge.

Place cutting edge on blade using Cclamps to hold. it In position.

Weld cutting edge to blade as shown In FIgure 2. Use E-70 or welding rod.

outtlng .....

Start at one end of rocket and weld toward center until one rod 18 used.

Repe&t at center of bucket. On suc-

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...

9010-5

"..T

.r ..,..

•

(~ ~ ,,~

'~ 1

nAM ASSEMI!l Y

BlAOi ASSEMBLY CUTTING EDGE

•

2. 3.

4. S. 6.

'\...

'\ )

1/4 ' (6.4"'1 FILLET 1/4" {6.4 om BUTT 3/16" {4.811m} FILLET

Figure 2 - Cutting Edge Welds

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...

9010-6

BUCKET TEETH Tooth Replacement

Tooth Shank Removal and Inatallatlon 1.

Remove all Shank welda using carbon arc rod or an acetelyne cutting torch.

Remove Shank and grind off any remaining weld on the cutting edge.

Refer to FigureS 3 and 4 for location and weld specific ations. Use a weld rod meeting A.W.S. speciffcation E-7018 and weld shank to cutting edge.

:-~ '

---..., h· , , ,

'-;(

!'-

f'=

••

Slide the new tooth onto the shank as far as It will go and peen each side into depression in shank.

,- -

;

L. • • • • • • ,

, , ---~ ,, ,,

Refer to Figure 4. Use a suitable tool and ruse the peened portion On each side oI the tooth and remove tooth from shank. The peened area may be beated with a torch to aid In removal.

,. . . . _- -'

rr=' '-.J • ,.,.

, :

,, ,,

ft, I f

, -.. , -::::-::.':::. :::::L:.::-:: ............

74" (ZSs( om)

H/4" 024_) g" (llS.' _) POSITI~

TIfTII AS CLOSE TO CORI(fR:

AS POSSIBl[ WHILE WllffTAINl1!G

OVERAlL

DI~NSIDN .

no",

Z. l.

3/S" (9.5 ... ) FILLEr· TWO PASS WHO WRAP COItlIfR: l/S" U.S _) 2- 1/2' (53.5 rII)

4. PEEMED DOWM PORTION

Figure 3

Figure 4

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9010-7

RETURNÂˇ TO-DIG 16 about bal! way up tapered surface on actuator rod. 'Ibentlghten bracket clamp.

General Return-to-dlg Is a feature that returns the bucket to a level (dlggiDgJ position after the bucket has been dumped. This 113 accompUShed by combining the Float and Rollback positions. The control lever Is held in Float by a spring loaded mechanical detent and In Rollback by an electromagnet (magnetic detent).

Start engine and run at low Idle. Raise loader arm to full belght and completely dump the bJ.cket.

Increase engine speed to full throttle and place control lever in Float and Rollback. The bJ.cket Should be in thedeBiredposiw tiOD when It toucbes the floor.

If the bucket rolls back too far, mcmt the switcb bracket forward.

If the rucket does not roll back far enough. move the switch bracket to tbe

The magnetic detent Is energized when the key switch Is in the On poslt10n and the switch roller 1s out of contact with the actuator rod.

When the actuator rod moves the switch arrn. the electrical supply to the magnetic detent is broken and the rooket spool returns to Neutral from Rollback. The control lever will remain in the Float position unW manually returned to NeutraL

rear.

Adju8tment

Rest loader bucket fiat on the fioor or 1n the desired position.

Loosen switch bracket claJql and remove switch bracket assembly. Do not disconneat wires from ewttch.

Check to see that switch roller lasligbtly above the centerline of the rod guide bor:e. Figure 6. Reposition switch as reqUired.

Reinstall switch bracket assembly. SUde bracket onto rod guide unW switcb roller

, o

"-;;:--:'- t-*=::;:==~ I. 2.

$IItrCH BRACKET SVZTCIt

1S1Ut

COO(RLIHE

Figure 5

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9010-8

ANTIROLLBACK General The anti-rollback llnkage Is !netalled between the bJ.cket oylinder bellcrank and control valve lever. Figure 11. The purpose of this l1nkap Is to prevent the bucket from rolling back too far When loader arm is raised to full beight. When the Unkage 1s properly adjusted. the side cutting edge on the Short Up bucket wUl be level and rolled back (ttIted upward) about 15" 011 the long lip bucket. The l1nkage Is adjusted at the factory and Should rarely require adjustment.

6. As the loader arm is raised to full height. the actuator woo causes the 1Dput rod to be pulled forward. 'Ibis in turn moves the leveling rod into contact with the bucket spool bellcrank.. As the bellcrank ia moved to the rear, the blcket spool 1a moved sllgbtly (featheT'ed) into the Dumppositionc8lls1.ngthe bucket to roll forward and. keep the side edges of the bucket nearly parallel to the ground.

Adjustment 1.

Adjust the length of the input rod. to 12-8/4" (324 mm) from center of clevie pin hole to center of ball joint. The offset ~ the rod Should be centered in the hole where it puses through the!ander. Adjust rod length at bOth anOs.

Raise the loader arm untll the bucket hinge pin 18 about 21"-22" (533-584 mm) above the floor and roll the bucket all the way back.

Check to see that the leveling rod touches the b8llcrank.. Adjust. length of puSh rod

Operation

as required. 4.

-' i>.

ACruI.TDA TUBE

2 • I fIPUT ROO 3. lEVELIN& ROO

•. 5.

80CKET SPOCl tELLCRANX 12· 3/.' (324 _I

Figure 6 Assume that the bucket is at ground level and rolled aU the way back. Refer to Figure

Raise the bucket to full height. The aide cutting edges should be:

Level H equipped with a short lip buckol

"b.

Rolled back (tilted upward) about 15" H equipped with a long Up bucket.

If bucket posltIoD is not as specified. shortell. the input rod to roll the bucket back. more or leugtheu the input rod to roll the bucket forward.

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9010-9

LOAOER ARM Removal

NOTE: If the machine Is to be used with the loader arm removed, the backhoe MUST be removed. Refer to Section 9100.

Completely retract the backhoe bucket and dipper. Then lower boom until bucket rests on the floor.

Raise loader arm slighUy above hood level and block in place using a suJtable

Disconnect return-tc>-dlg wiring harness at limit switcb on loader arm. CUt harness tie straps and place harness out of

way. 7.

Attach chain hoist to loader arm in front of muffler. Remove slack from chain.

Remove snap rings and washers from loader arm pivot sbaft and drive shaft out of frame. Have someone available to bold Shaft as it is driven out.

Start engine and back machine out of loader arm. Use care if backhoe was not

support under the bucket or loader arm croS8m~mber .

Remove the IUt cyUnrier rod eye pIvot p1.ns. Have someone available to prevent the cyUnder from falling wben the pin 18 removed.

If chain hoist can be used, attach holst to bucket and lower bucket to the floor.

If chain hoist cannot be used, reinstall the rod eye pins and lower the

bUcket to the floor. Then remove the pins. 4.

Rest bucket flat on the floor and disconnect the hose to the bucket cylinders (and clam cylinders if so equtpped) at the rear of the loader arm. Remove the antirollback actuator tube and bellcrank p1vot bolt and related

parts.

,..moved.

10.

U machine is to be used without the loader. disconnect 11ft cylinder hoses at manifold tubes on eacb side of machine and remove the lift cylinders. install plug part number 218-776 in mani{old tubes.

11. Install cap mlt part number 218-755 on the bucket and clam cylinder hoses.

Installation 1.

Loader arm installation Is the reverse of removal.

Refer to the various illustrations In this section to aid in installation and assure correct hydraulic line connections.

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9010-10

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....".,

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)"-""~ i:pifr,.

,'-

,.;{~

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f,' "

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1~ln.

Figure 7 - Loader Arm

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9010-11

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Figure 8 - Basic Hydraulic InsW la.Uon

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9010-12

•

Figure 9 - Lift Cylinder Hydraulic installation

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9010-13

ISIMI

Figure 10 - Bucket Cyl inder Hydraulic Installation

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9010-14

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711662

Figure 11 - Loader Arm Auxiliary Hydraulic lnstallation

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90~O-15

.... '/"'"

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Rtl1m4-TO-DI6 PAlIYS

1. ACTl.IATOR ROD 2. ROO &tUOE 1....... 4. SVlTO! BRACKET 5. SNITO!

•

ANTlltOLi.l!.ACK 1I1fl:AGE 6.

PUSH ROD

ACTUATOR TllIE

8. LINKAGE BEllCRAHK 9.

10.

INPUT ROO

LEVELING Ron

Figure 12 _ Return-to-Dig and Anfuollback IJnkage

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9010-16

{:} '. ---7 , '.

SPAUR USE!) \H PlACE OF ClAM SPOOL LEVER 011 TIIO sPOOC VAlVE COHTROl LEVER IIISTAUATllJIt.

NO.,..

Figure 13 - Control Lever In's tallation

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9010-17

Figure 14 - Clam Bucket

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9010-18

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1. â&#x20AC;¢:'

NOTal Fl<ONT ~OUMTERWEIGlfTS WE tOO 500 AAll 700 POUNDS (22' AXO 317 kg) . USE SUITABLE l iFT t H~ EQUIPMENT WHEN REMOVING AHO INSTAlLI NG COUIfT ERllttGKT.

l \lUl

Figure 15 - Front Counterweight Installation

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9010-19

1ItOT., COUN'TE1IIIEIGHT

VE1611S Al'PIIOXlMTELT 1.(25 PWIIOS ( 6.(6 kg). USE SUITAIILE UFTIIIG EQUIPMENT WHEN REMOVIIIG OR IHSTAlUN!> COt!NTIJ!WE IGIIT â&#x20AC;¢

Figure 16 - Rear Counterweight Installation

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Section

9033 THREE POINT HITCH

J I Case A. Tenneco Company

C. E. Dlv. 9-66015 February 1976

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9033-2

REMOVAL AND INSTALLATION lever lnto the Lower position and the bitch will be raised out of the

Removal Park the machine on a level surface and lower the implement. If equipped with a cab, remove the rear closure panels around the bitch.

At the rear of the tractor there are two tension rod assemblies. Loosen the upper and lower nuts on each tension rod. Then remove the klik plns from the upper mounting pins.

Use the lift and pltch control levers as required to remove the weight of the hitch from the upper mounting pins. Then drive the mounUng plns out.

lower support arms. 5.

Connect the return hose to the pressure tube on the tractor. Be sure the coup-

lIng Is fully engaged. Carefully drive the tractor away from the bitcb.

If the hitch is to be left standing for

an extended period of time, block up the bitch as shown in Figure 2 to prevent loss of position.

Remove the hitch from the lower support arms. Use a cbain hoist or;

If the rear mounted implement weighS less than 500 pounds (227 kg), use a hoist or jack to 11ft the bitch out of the lower support arms. Raise the h1tch until the control valve mounting arm clears the tenstOD rod.

s~.:~

Figure 2 - Ritch Prepared for Storage

~"*,

~::.'

,~,

Carefully drive the tractor forward about one foot. Stop the engine and disconnect the pressure and return hoses at the quick disconnect couplings.

Installation

:r' ..

Figure 1 - Hitch Raised With Jack b.

If the rear mounted Implement weighs more than 500 pounds, (227 kg), use the lift cylinder to raise the hitch out of the lower support arms. Slowly move the 11ft control

Back the tractor into the hitch until the bitch mounting frame enters the lower support arms. Stop the engine and connect the hydraulic lines to and from the control valve.

Carefully back the tractor completely into the hitch. Then lower the hitch into the lower mounting arms.

Use the Uit and pitch control levers as required and alIgn the mounting frame with the upper support arms.

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9033-3

Drive the upper mounting pins in and secure in place w1th klik pins.

Make sure the iov.-er tension rod nuts do not contact the upper support arms

and torque the upper nuts to 140-170 foot - pounds (189-230 N m).

Tighten the lower tension rod nuts until snug and retorque Ute upper nuts to 450-550 foot-pounds (590-744 N m).

Figure 3 - Three Point Hitch Only Basic Hydraulic installation

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9033-4

I. 2.

lin CYLIHOÂ£R

TILT CYLINDER

PITCH CYLINDER

RESTRictED FLOW ELBOWS.

LETTER R STAHPfD ON ELBOW

Figure 4 - Three Point Hitch Cylinder Hydraulic Installation

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9033- 5

)

~ 0.IO

! 10

",~ " "

•I x 0•

~.'

e• ,

'~'"..·co10 150120

I. Z.

S. O.

FIW£ LJ FT AA.'1 DRAFT ARM AH1I SVAY B LOC~ (z) BLOCK RETAINER CONTROL 'IAL '/E 1OJUT !1lG 8RACKli

7. 8. 9. 10. 11 .

L1Fl AAH SHAFT UPP ER MOUNT ING PIN (2 ) SPACER (2) SNAP RING LOWER I'()UN'T ING PIN PARTS (2 EACH)

12. PITCH CYL INDER 13. LIFT CYL INDER 14. TILT CYLINDER 15. STRUT 16. BUSHING

Figure 5 - Three Point Hitch

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Section 9061 ROPS CAB AND CANOPY

J I Case A T9f'lI'\8CO

Compa~y

C.E. Div. 9-66015

February 1976

-.~

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9061-2

ACCIDENTAL UPSET The ROPS is an energy absorbing safety device. Once it has been subjected to an upset or some other form of impact (such as striking an overhead abutment during travel) it should be replaced so that you win have the same degree of protection originally provided.

The ROPS and mounting, operator's seat and mounting, seat belts, and any accessories. wiring, etc. within the ROPS Should be very carefully inspected after an upset. and all broken or damaged parts should be replaced immedIately. DO NOT ATTEMPT TO STRAIGHTEN OR WELD THE ROPS.

MAINTENANCE AND INSPECTION Every 500 hours or twice yearly, whichever comes first. the following should be performed 1.

Check torque on the ROPSmountlngbolts and retorque to specifIcations if required.

See Figure 2. 2.

Inspect the operator's seat, seat mounting, and seat belt. Tighten bolts to specifIcations. Replace damaged or worn parts.

SAFETY PRECAUTIONS Do not makv an, fwld modifications to HOPS s\wh as ..... eld~ lng a(Tessorles to, or drlllll1;!: holes

I\..

Special

hardware

WARNING:

In It.

often USf'd far mounting and ancharin!: OptÂˇ rator protective dc",ices. H('plac('m'~nt parts must be those listed

40-14

Do not Install attachthat will cause the total gro!;s wdg"ht of the machine to exceed the

in the Case Parts Catalog.

40-16

WARNING:

I\.. ~

m'~llts

we1h>ttt shown in the "for maximum gross vehicle welght" column of Ute HOPS label.

40-15

CAUTION. The battery must be equipped with nanspill caps. If the . . fuel tank cap is replaced. use part spcdfll'd In parts catalog. 40-17

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9061-3

TORl}Uf 0fI~[ TO TO

,. ~(lRQU[ I.

5 12;:~O 6'J

TO 50-

n -tSS FT-lBS n _t1lS

{ 3'-~7 MOIl

0 17 n ~I"'I i~:81 ..

"'"'"

Figure 1

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9061-4

,; ./

.~ ~-

2. l.

TOROU£ TO ]00-]20 FT-LBS (115-161 N .).

TORQUE TO 200-2.0 FT'lBS (271 - 325 H IOl. TOItlJJE TO 65-85 "_LaS (88.115 N .)

GRA£lE a IIOUS; 00 NOT SlIISTIMt GRADE 8 IIOLTS; 00 IIOT SUBS7mrn:

FIgure 2

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Section 9100 BACKHOE

J I Case

C, E. DIV, 9-66015

A retlneco ComOM'f

February 1976

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9100-2

TABLE OF CONTENTS Backhoe ReDlOval . . . . . . . . . . . . • • . .. .. ••.•..••..•.••••••••••••••• 9100-3 Backhoe Installation . . . . .. .•. . ...•••.•.•••.•.••••••• . . . . ••.•..•• 9100-4 SWing Tower Removal and Installation ....••••• ••... ••.••.•••••••.•..• 9100-5 Disassembling the Backhoe . . . . .•.• •..•.• • • •...••••••...•...• ••. .. 9100-7 Assembling the Backboe ..•....•.•••••. • . . • . . . . . . . . . • . . • . . • • . . . . • 9100-8

DIpper Extension . . . . . . . . ....•••••• •• ••• • •••.••••••••••••••••. 9100-10 Bucket Cutting Edges and Teeth .....•••••••••••.•••..•. . ••••••••.. 9100-12 Swing Pivot Bush1ngs and Bearing Washers •••• .• •••••••••....•.•••... 9100-1 Mounting Frame, Swing Cyllnder and stab1li1:er Installation •••.•.•••••••••.• 9100-16 StabUuel." Cylinder Hydraulic Installation ••••. • ..••••••••...••••.•••.. 9100-17 Swing Cyllnder Hydraulic Installation •••••. , •••••••••••••••.•••••..•. 9100-18 Exploded View of Backhoe ....•••••.••••. • •.••••.••••.•••••..•••• 9100-19 Boom, Dipper and Bucket Cylinder Hydraulic Installation •..• .•.• .• .••.••.. 9100-20 Exploded View of Extendable Dipper .••••••.•••• • ••••••••••••••••••• 9100-21 Extension Cylinder Hydraulic Installation

. . . . . . . . . . . .. . . . . . . . . . . . . . . . 9100-22

Boom Lock Hydraulic Installation ....••••.•.•••••••.•••••••.••••••• 9100-28 Control Tower Installation ....•..••••••••• ..• •••. . •.••••••••••••• 9100-24 Control Lever Installation with Foot Swing

.. • • ••• .. ••.•••.....•••.••• 9100-25

Control Lever Installation with Hand SWing

. . . . . . . . . . . . . . . . . . . . . . . . . . . 9100-26

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9100- 3

BACKHOE REMOVAL 1.

Park the macbine on a hard level surface and lower the loader bucket to the graund (floor).

Form a trIpod with the backhoe as illustrated In Figure 1. Lower the stab1llzers untU they touch the grOOM (floor).

Loosen the upper Ue rod nut on each

side. The nuts are torqued to 450-550 foot-pounds (610-745 N m) and may be diHicu1t to loosen. 5.

Remove the upper mounting pin retaining bolts. Disconnect the dipper light wire U so equipped.

Start the eogtDe and runatlowidle. Raise or lower the boom and stabilizers as re-

quired to remove weight of backhoe from the upper mountlng pins and remove the mounting pins.

U machine is equipped with a canq)y, use the stabUizers and raise the backhoe mounting frame out of the lower support arms.

If machine Is equipped with a cab, proceed as instructed to prevent unnecessary damage to the c ab. L

Figure 1

Disconnect rearwindoww1perwiring and raise the rear window. Reln01'e

lower panel acroSI rear

window.

At the rear of the machine there are two tension rod assemblies tbathold the back-

hoe In place. Remove the filler plate between the floor plate and the backhoe mounting frame o r remove plugs inWler plate to gain access to the upper tie rod

Start engine , run at low idle and raise stabUizers about ODe foot (300 mm) above the ground (floor).

With the engine running at.low Idle, r aise the boom slowly to pivot the bac khoe mounting frame away from

nuts, Figure 2.

the machine. Pivot the mounttng frame far enougb to avoid contact between the cab and swtngpedal guards. e,

Use the stabilizers and raise the

backhoe mounting frame out of Ule lower support ums. 9.

Carefully move the machine forward about one foot (300 mm) and disconnect the supply and return lines.

10, Connect return hose to supply tube at rear of machine . . Ulustrated In Figure

Figure 2

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9100-4

Figure 3

BACKHOE INSTALLATION 1.

Line up machine with backhoe and backup close to the backhoe mounting frame.

Stop engine and cormect the supply and

return lines. NOTE:

required to align the mounting pin holes in the mounting frame with the upper support arms. 5.

Raise the mounting frame with the stabilizers as required to aid in pin installation. Secure pins in place with nuts and bolts.

If machine is equipped with a

cab. be sure the backhoe mounting frame Is pivoted away from the machine as required for removal before completing step 3. 3.

Very carefully back the machine into the backhoe. If necessary. raise the mounting frame with fue stabilizers. Lower the mounting frame onto the lower support arms.

Carefully raise or lower the boom (which pivots the mounting frame in or out) as

Drive the upper mounting pins Into place.

Make sure the lower tension rod nuts do not touch the upper mounting arms and torque the upper nuts to 140-170 footpounds (190-230 N m). Then tighten lower nuts until snug and retorque upper nuts to 450 - 550 foot-pounds (610-745 N m).

Reconnect dipper light wire if ped.

equip-

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9l00-5

SWING TOWER REMOVAL ANO INSTALLATION Removal 1.

Completely extend the backboe and rest the bucket on the floor. Place a suitable support under the boom and dipper pivot to help stahlllze the backhoe.

Move the boom, dipper and bucket control levers In both directions to equaJlze clrcult pressure. Then remove the front cover from the control tower.

Number or otherwtde Identify the control valve ports and hoses to assure proper assembly. Then disconnect the bucket and dtpper boses from the control valve and the boom hoses from tubes from cOntrol valve. Also remove bose clamp from inside the swing tower. Plug or c ap all openings.

InsWI cap (part no. 218Âˇ335) on hose to closed end of boom cylinder s to hold swing tower in proper posltion.

If equipped with an extendable dipper, remove the bose guard on bottom of boom and disconnect hoses from tubes. Then free the hoses from the swing tower.

Remove the swing cylinder rod pivot pin retainer from bottom of swing tower. Drive the pivot pins out the bottom of the swing tower.

Remove the boom latch mechanism from the swing tower and Install a rod (1" dill. x 18") (25 mm dta. x 457 mm) in the boom latch pivot pin holes. AttaCh a chain to the. outer ends of the rod. Then attach a chain hoist to the chain and remove the slack

Remove the snap rings from the swing tower pivot pins and remove the pins.

Raise the swing tower to take weight off bottom pivot. Then slowly and carefully

move the tractor forward. 10. Prov1de additional support for the boomj Use a chain boist or block up. Remove the retaining bolts from both boom cylinder pivot pins. Then remove a pivot pin and lawer the boom cylinder (repeat for the remaining boom cylinder). 11. Remove the retainer from each boom pivot pin and remove the pins. Then remove swing tower from boom.

11 \61 S

Flgtlre 4 - Removing/Installing Swing Tower

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9100-6

Installation

pivot pins and secure in place with snap rings.

Attach chain hoist to swing tower and pos1t1on swing tower to boom. Then install the boom pivot pins. Secure pins in place with pin retalning hardware. Position a boom cylinder to the swing tower and install the pIvot pin. Coat one side of a washer with grease and position on outside of swing tower ear. Make sure bole in pin and cylinder are aligned and drive pin in until boles are

aligned. Secure pin in place with boll Repeat for the remaining boom cylinder. 3.

Back the tractor into position to mount the swing tower to the mounting frame. Install the upper and lower swing tower

Remove Chain hoist and rod from swing tower.

Align swing cylinder rod eyes with swing tower and install pivot pins through bottom of swing tower. Secure pins in place with pin retalner.

Install boom latch mechanism.

Connect hoses to control valve and tubes. If ooses and ports were not identified, refer to Figures 15' and 17 for proper connections.

Reinstall front cover on control tower.

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9100 -7

DISASSEMBLING THE BACKHOE This procedure outlines the complete disassembly of the backhoe. There may be occasions 'when complete disassemNOT. t:

bly Is not required, therefore use the step s necessary to remove the affec ted component(s). Refe r to Section 4090 'Aben removing

Attacb a chain hOist to the dipper arm. Move the dJpper control lever in both directions to equalize circuit pressure.

Place a block of wood under the dipper cylinder to provide support when the rod pin is removed. Then remove a snap r ing and wasbe r from the dipper oylinder rod pivot pin and remove pivot pin.

Remove a snap rlngandwasherfrom the dipper arm pivot pin and remove pivot pin.

Uft the dipper away from the boom and lower the dipper arm to the floor.

cylinde r s for repair. NOT.

a: Shims are used at pivot points

to reduce s ide p lay. When disassembling the

backhoe, note the number and location of these Shims for proper parts positioning during assembly. Refer to Figures 14 and 15 to aid in disassembly.

Bucket Removal 6. 1.

Lower the bucket wi th bottom of bucket

If the backhoe Is equipped with abydraulIcally extendable dipper arm:

flat on the fl oor. L

Remove a snap ring and waSher from the h ...o pivot pins that must be removed. One attacbes the bucket to the dipper arm and one attaches the l inkage to the bucket cylinde r rod eye .

both direc tions to equalize circuit pressure. b.

Disconcect hoses to the extensloncy1inde r at the tubes secured to the boom and c lose openings with clean caplugs.

Place a hlock of wood under the dipper cylinder to prOVide support when the roc:\ pin Is removed. Thenremove a snap ring and washer from dipper cylinde r rod pivot pin and remove pivot pin.

Remove a s nap ring and washer from

Dipper Arm Removal 1.

Remove b.lcket as Instructed under Bucket Removal.

Extend the dipper arm and lower the boom unttl the end of the dipper arm rests on the floor.

Move the bucket control lever in both directionS to equalize circuit pressure. Provide support (chain hoist) for the bucket cylinder and re move a snap ring and wasber from the cylinder pIvot pin. Then r e move pivot pin.

Free the wcket cylinder from the dipper arm and disconnect boses at bucket cylinder and lower bucket cylinder to the floor . Then disconnect bucket boses at tubes secured to boom and close all openings with clean caplugs.

11' the backhoe Is equipped with the standard dJppe r arm:

Attach a cba1n holst to the dipper arm.. Them move control lever in

the dipper arm pivot pin and remove pivot pin. e.

Lift the dipper away from the boom and lower the dipper arm to the floor.

Boom Removal 1.

Remove the ~cket and dipper arm as previously instructed.

Attach a chain hoist to the dipper cylinde r . Then remove the dJpper cylinder pivot pin retaining bolt and pivot pin.

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9100-8

NOT_: As the remaining hoses are disconnected. number each hose and its connecting point to assure proper assembly.

der as required and c lose openings with clean caplugs. Then remove the pivot pin retaining bolts from each cyllnder and rod pivot.

Remove the bose clamp lnside the boom. Then remove the hose guard from the bottom of the boom if equipped with an extendable dipper arm.

Carefully move the dipper cylinder away from the cylinder mounting bracket. and disconnect hoses from cylinder. Close openings with clean caplugs. Provide suitable support for the boom and move the boom control lever in both direct10ns to equalize circuit pressure.

Attach a chain hoist to a boom cylinder. Remove the cylinder pivot pin. Then drive the rod eye pivot pin !rito the rod eye to free rod from pin and lower cylinder to the floor. Repeat for the rem alnng boom cylinder.

Attach a chain hoist to the boom and disconnect the remaining hoses from the boom.

Disconnect hoses from each boom cylin-

Remove the boom pivot pin (2) retaining hardware and remove the pivot pins. Then lower boom to floor.

ASSEMBLING THE BACKHOE NOT.: Install shims in same location and quantity as noted during disassembly.

Connect hoses to the boom cylinders and tubes attached to the boom. Ifboses were not numbered or otherwise identified during disassembly, refer to Figure 15 for proper connections.

The boom can now be raised or lowered bydraulically. Position the boom in a suitable position, and with the aid of a chain boist position the dipper cylinder over the boom.

Refer to Figures 14 and 15 to aid in assembly.

Boom Installation 1.

Attach a chain holst to the boom and llit boom into position to attach to the swing tower.

Allgn the boom with the swing tower and install the boom pivot pins. Secure the pins in place with the pin retain1nghardware, Figure 15.

Connect the hoses to the dipper cylinder and pOSition cylinder in mounting bracket. Install pivot pin and secure in place with bolt and nut.

Posit1on a boom cylinder to the swing tower and install the pivot pin. Coat _one side of washer with grease and place on outside of swing tower ear. Make sure hole in pin is aligned with bole in cylinder and drive pin in until the holes are aligned. Then install the pin retaining bolt. Repeat for the remaining boom cylinder.

Install bose clamp inside of boom, making sure hoses are properly positioned.

If equipped with an extendable dipper, connect hoses to tubes on bottom of boom and install bose guard.

Dipper Arm Installation 1.

Align the cylinder rod eye with the rod pivot pin. Make sure the bolt bole in the pin and eye are aligned and drive pin into the rod eye until the holes are aligned. Secure the pin in place with bolts and nuts.

Attach a chain boist to the dipper arm and position the dipper on the boom. Use the same number of Shims between the boom and dipper as were removed. Install the dipper arm pivot pin and secure in place with waShers and snap rings.

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9100-51

Coat the sides of the dipper cylinder

rod eye with grease and place a washer on eacb side of the rod eye. Align the rod eye with the dipper arm and install the pivot pin. Secure the pin in place

If equipped with an extendable dipper arm, connect the extension cylJnderhoses to the tubes secured to the boom.

with washers and snap rings.

Bucket Installation

Position the boom and dipper arm to aid in installing the bucket cylinder. Attach a chain hoist to the bucket cylfDder and position oylinder over dipper arm. Connect hoses to buoket cyllDder and tubes attached to the boom.

Position bucket to dipper arm and install pivot pin. Secure pin in place with washers and snap rings. Extend or retract the bucket oylinder

to align the cylinder rod eye with the 4.

Coat the sides of the cylinder eye with grease and place a washer on each side of the eye. Then carefully move the cylinder into position and install the pivot pin. Secure the pin In place with w8.8hers and snap rigs.

upper and lower bucket control links. Coat the sides of the rod eye with grease and place a washer on each side of the rod eye. Align bucket links with rod eye and install pivot pin. Secure pivot pin with washers and snap rings.

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9100-:1.0

DIPPER EXTENSION 3.

Removal 1.

Remove rocket as lnstructed on page 9100-7.

Make sure dipper extension is fully :retract&d and position boom and dipper to aid

in removal

Start the engine and SLOWLY extend the extension cylinder to bring rod eye into altgnmoDt with bole in dipper extension. If the rod eye contacts one of the bosses inside the dipper extension and pushes the extension out, move the extension sideways to align rod eye with bosses.

of dipper extension. /)..

Remove snap rings and waShers that secure bucket links to dipper extension

. .

WARNIN G .

,':

1'(' ',_

\,t\1

" ~'.

.•

;',1

Ilng "

t .... ... ~ t"

I' •

and remove rocket links. 4. W ARNI NG: !-.,·,! ~.Ig"~ ,\1( , . , ,,,, ] , , , , , , ,

.:!,

. .

~' : .

\ \.,

\' . '

\ , d.

. I

•

, ' -

Remove pin that attacbes sliding collar to dIpper extension.

The dipper extension weighs approximately 230 pounds (104 kg) and 1s approximately 7 feet (2133 mm) long. Pull !he

NOT.: Use care in moving sliding collar as tile weight of the collar will cause it to sUde downward on the dipper arm when the pin end is raised.

dipper extension out of the dipper arm about hal! way and attach a cha1n boist to the extension. 6.

Install the collar and rod eye retaining pin. Then install the bucket l:ink8 on pin with links on top of wcket pivot bosses.

Secure pin with washers and snap rings.

Continue pulllng the extensioD from the dipper arm whtle being alert for an unbalanced COnditiOD v.hen the extension Is free of the dipper arm. Lower the ex-

tension to the floor,

Replacing Dipper Extenalon

Installation 1.

After the rod eye is aligned with the pin bole, grasp the sliding collar and move the collar into alignment with hole in dJpper extension.

Block up rod end of extenslon c ylinder in dipper arm about 1 inch (25 mm) with a small piece of wood. Also make sure the rod eye 1s straight up anddown.

Attach a chain holst to the dipper extension and push the extension into the dipper arm about hall wsy. If necessary, drive the extension into 1I1e dipper arm.

Install bucket as

instructed

on page

9100-9.

Wear Strips 1.

Remove dipper extension.

Use a chisel to break 'Wear strip vrelds. Then remove remaining weld with a grinder to provide a flat surface tor the

new wear etrlps. 3.

Refer to Figure 6 for location and weld specifications and weld wear strips to extension. USE E-7018 welding rod.

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9100_11

Guide Blocks Guide blocks are attached to the sliding collar1:o reduce clearance between the collar and dipper housing. The blocks are held in place with cap screws and lock washers. Whenever installing guide blocks, make sure chamfered side 1s toward tbe dipper housing. Figure 5,

)

GU!DE BLOCK 2. DIPPER HOUSING 3. SLIDING COLlAP. 4. LOCI:. IUlSHEIT 5 â&#x20AC;¢ CAP SCREW 111 ~ 6. CHAMFERED EDGE I.

Figure 5 - Guide Block: Installation

lEI::[9 9 ~~~\)~~~~~~~~~:::;~~ t

2 1.

In" (1 7 mol

liB" (3 . . ) FILLET WolD otI EACH or ALL STR IPS

I" (2S _1

2" (50 mnl

tl.N0 WTlI E"OS. 1/8" (3 _j FILLET WELD I " (25 rrml tONr. ON 7 ' ( 178 ~J CEN TE RS. BOTN SIDES All STRIPS . SRW TlUS CCRl'lER ON STRIPS liT THIS tND.

151&la

Figure 6 - Wear Strip Location and Weld Specifications

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9100-12

BUCKET CUTTING EDGES AND TEETH NOTE: If bucket Is not removed for repair, dIsconnect alternator leads and unplug -voltage regulator.

Refer to Figure 8 and weld cutttngedgeto bucket. Use a weld rod meeting A. W.S. spec1!1cation E- 7018.

Bucket Teeth Wrap Around Cutting Edge Tooth Shank Removal and Installation Removal and Installation 1.

Remove the bucket teeth if so equipped. Use carbon arc rod or an acetelyne cutting torcb to remove welds. Remove all cutting edge welds using carbon arc rod or an acetelyne cutting torcb.

Cut through the corner of the bucket and cutting edge.

Remove the cutting edge and grind off any remaining weld and/ or excess metal to provide a smooth surface for the new cutting edge .

Remove all shank welds using carbon arc rod or an acetelyne cutting torCb.

Remove Shank and grind off any remaining weld on the cutting edge.

Refer to Figures 7 and 9 for location and weld specifications. Use a weld rod meeting A. W.S. specification E-7018 and weld Shank to cutting edge.

Tooth Replacement

Place cutting edge on bucket, using Cclamps to hold It In posItion. Using a weld rod meeting A.W.S. specification E ~ 7018. fill opening made in each corner,

Refer to Figure 8 and v,-eld cutUng edge to bucket. Use weld rod specified in step 5.

Install bucket teeth. Refer to Figures 7 and 9 for location and weld specifications.

Refer to FIgure 7. Use a suitable tool

and raise the peened portIon on each

side of the tooth and remove tooth from Shank. The peened area m.ay be heated with a torch to aid in removal On heavy duty buckets, drive out pin. Slide the new tooth onto the Shank as far as it will go and peen each side into depressIon in shank or drive pin lnte place on heavy duty blckets.

r------- : I .~ •

If old tooth shanks are to be used, remove any remaining weld before reInstalling.

L. _ __ ____

4J/

Side Cutting Edges Removal and Installation 1.

Remove all cutting edge welds using cartxm arc rod or an acetelyne cutting torch.

Remove the cutting edge ancigrindoffany remaining weld and/ or excess metal to provide a smooth surface for the new cutting edge.

Place cutting edge on bucket, using Cclamps to bold it in posItion.

...._... ---- ____ ......, ___________ ---------------,

'---

~_ 4,

3. •.

3/8" (9.5lT111) FILL ET.11IO PASSWELC WRAP CORHER 3/B" (9.S ~) 2-1/2" (63.5 _) PE[HEC DCNN PQl!T1(»1

Figure 7 - Bucket Tooth and Shank. Installation

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9100-13

STANDARD TRENCHING BUCKET

HEAVY DUTY TRENCHING BUCKET

--~~BELLHOLE BUCKET

,, ,, ,,

," ,

........

SHOVEL BUCKET

-I

l. 2.

H /1 6" ( Ud on) 1-7/S" {41.6

' . 5.

I-lIZ· /3!.1 ~ 1-3/16" (JO.l".,,'

2-3/S"

{ ~.3

OIl

DITCHING {VI BUCKET 6.

1-1/16'1 36 •5 ..1

1-511'- ll.) no ) ll1'- {4.S _I FlUff

1/ 4" (6. ' . . I F1Llff 5/16- fS ml TW 1'.0.55 VELO

S. II).

1 ~1~1

Figure 8 - cutting Edge Weld Spec1fJcatlons

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9100-14

I~/r)

: :

'-;J..

---4

1-'- --,,

1- - -1

r --,

I I

I I I

r--, ,

I , '

11010

IS - 1457

24"

610

Iml /1m

30- (7 62 ""

36" ( 914

4 . )6" (91 4 S.

nrnl

)

2 CEN1(H UNE I S" (4 57 mil) l~ /1m ) JO" 762 36 - (n 4 OIl

I ,.

I I

1. 2.

. ;:

BUCK ET - 9-5/S" (241.5 "", ) .19-1/4" (489..o) OVERAll tUGKH - IZ-~/B 'I~ ' ~I ' 25-1/4 " on) OVEAALL

BUCK{T BUCKET BUCKET BUC KET

aunn -

1642

15-5/S"

397 .... 31-l/4 " 794 "") OVEJWl. 18- 5/S" ( 413 mI. 37- 1/4" ( 946 _\ OYEAAl.l 2-1/8 " (54 no) 3-1/8" (79.4 mm )

6-1 /2" \1 65

BUCKET - 9-3/ 4"

"'"I

243 mD

BueHl - Z-314 " (70 an)

BUCKET IJ'ILY - 6-1/8- (156 an) . 12-1/4 " (312 .... ) OVERALL PO~IT!O:1 10 0T~ SAAN ~ IS CLOSE TO CORNER AS !'OSSIBLE ANO AAINTAIN OVERALL Dlt!Â£N$lil'I . ~L BU( K(~S ( XC[7T 12- (305 ~ ) 3UC KET _ lIZ" ( 12. 7 n.j . POS I TION TOOTH SHAH[ AS CLOS E 10 CORNER AS POSS IBLE ~ILE tlA lNTAl NING THE 1/ 2" (\ 2.7 m ) .vtD OVERAL L DIMENSIONS . CENTER TOOTH USED ON 12" (305 ~) AND 30" (762 mm) BUC~ETS ONLY 12" (305 ","

F igure 9 - Bucket Tooth Location

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9100 ~ 16

SWING PIVOT BUSHINGS ANO BEARING WASHER Bushings are used in the top and bottom m ounting frame pivot ears and the bearing washers are used at the bottom plvot; one on top of the mounting fr ame and one OD the swing tower. Figure 10.

Replacing Bushing and Bearing Washers

â&#x20AC;˘

Separate swing tower f:rom mounting frame as instrocted on page 9100-5.

'When replacing the bushing or a bearing washer at the lower pivot, it Is recommended that all the parts be rep laced at the same time.

Break washe r

tack welds with a

chisel b. L 2. 3. 4.

8EARING WA SHER TAC( WElO I" FOOl!; PlACES 90" MAAr 5W litl TOIItlI i'WJ1M1~ FfWIÂŁ

BUSHING

Drive bushing out of mounting frame.

Drive bushings into mounting frame until flush with bottom of pIvot en.

Center benJng washer on pivot pin bole and tack weld in place as instructed in Figure 10. Use a C- clamp to hold swing tower washe r in place.

nl~ ]

Figure 10

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9100 - 16

6 1

1. 2.

TORqUE TO 520-640 FOOT-POUNDS (70~ - 867 N m) PIVOT BEARING WASHER . REFER TO PAGE 9100-15 .

751644

Figure 11 - Mounting Frame, Swing Cylinders and Stabilizers

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9100-17

, â&#x20AC;¢

FIgure 12 - Stabilizer Cylinder Hydraulic Installation

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9100-1 8

, â&#x20AC;¢

I. Z.

RESTRI CTOR MUST BE INSTALLEO IN EACH CYL: ND(R. SHALL END FIRST. TU8[$ USED WITH llANO SIoIIHG

CONTROLS.

Figure 13 - SWing Cylinder Hydraulic Installat10n

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9100-19

@(f@ _ _ _.....

I . USf A$ p.£QUIRrO TO Z.

LI~IT

OI'PfR

TO alXJl "'O'/EllEtlT to . 070 " I!. 78 ""') IJ! US[ HT'OEtN 500H Cnt~Du MD OIJTS1M

L~S

Of SWIHC TGWfR AS RfOUIREO, BOTK CYLINDERS

I. USE ~S OIP'[lt

~(OUIRED

TO LIMIT SUCKEr TO

I(lYfH(1ff TO .25" ( ,.4 ... ) DR

LESS

RIJUH PIN · I'IU. EICEPT II" (305 ...,1

12" (305 ""')

usc

sucur

PI"

WASH£RS AS '£OUIREn TO CtNTfR PIN IN !ODI' IIlTl! MIHIKlI [NO PLAT

Figure 14 - Explode d View of Backboe

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9100-20

~ 2.

Figure 15 - Boom, Dipper and Bucket Cylinder Hydraulic Installation

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9100-2.1

•

, W @

•

, ,<.

,.•• •• ,.,.•• ••

DIPPER HOUSI~G DIPPER EXTENS ION SlIDIH& toll.AA W£AR STRI P (s) WIDE ptaTE GUIDE aLOC~ (ll HTEIISIOII CYlINDER IUUIT Cl'LlllDElI.

•• 10.

\IlSII£R. t,lSf nil! [ACH SIIli OF DtP1'Ut en [N!l[P. ROO UE

NCO 8£TWEDI !./lAp RINGS .IJt1I IClUSllIi AS IlI:OUIR£ll. lISE AS REQUIRED TO OBTAIN .070· (1.7a ....) AAU~ CLEARANCE

ICTWE[N

AND DI PPER ll . SPA:ER. USED IIITH 5TAHOARD ~

""..

OIPPER PIVOT PIN

>S . 10 .

SIlSHI",

lB . 19.

FLAT IIASHER SPJ,CU.

". 11.

EXTENSION CYl. PIN DIPPER CYL. PI" WtKrT ClL PIM s~p

UIIG

Iuc.KrTS ONLY

1"'"

Figure 16 _ Exploded View of Extendable Dipper

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9100-22

n ,r' .' .)

H o

,',

A..'...

'-",OW

"IMO

I. 2. l.

CONNECTEO TO

~Al V[

A PQIH

COMmCTEO TO ~Al VÂ£ B PORT CYLI.UlR AQfAT[ D 150" ro~ (LARITI

Figure 17 - Extension Cylinder Hydraultc Installation

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9100-28

1. CONHECTED TD BOOM SECT 10M B PORT

Figure 18 - Boom Lock HydraulIc Installation

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9100-24

â&#x20AC;¢

F igure 19 - Control Towe r Installation

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9100 - 25

J .

/1""- C

, , .' .' , .' ' .,

. t..J

~.'

!. 2.

ButHl OI PPER

AtlJUST LENGTH Of STAB ILI ZER CLEV IS ROO TO POSITION LEV(R ST1!AI GHT UP AND DOWN

IF EOO IPPED WITH EXTENOAHOE. COh'T ROL LE VER

BOOM

5TA8 1 Ll ZE~

,4' - ADJUS T eUCKli , B~

CLEVI S RCDS TO

D I P ~ER 08T ~IN

A!lD

IS IN STALLED I N "tACE OF SPAC ER IS' - ADJUST LENGTH Of SWING PEDAl CLEVIS ROO TO OBTAI N PIIOI'ER POSITIOtI

)

\ ~

Y 75165)

PROPER POSlTIOH

Figure 20 - Control Lever Install ation with Foot Swing

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9100-26

, ,

'""

BOCW AIIO SlUNG

2. auCX£T ~~D DIPP[R 3. STABIUl£R •• 86· - ADJUST LtMGTH or STABILIZER CLrYIS ROO TO OBTAIN PII{lPER POSITI~

Z9· - ADJUST LENGTH Of CLEVIS ASSEMBLY ATTACHED TO CONTROl lrY£RS I AND 2 TO OBTAIN PRflPER POSITIOlI

iF Eflt/ IPPW W1Tl1

EXT[.~!)AHOE.

CONTRflI. lUU

IS INSTALLED IN PLACE OF SPACER

1S16~

Figure 21 - Control Lever Installation with Hand Swing

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